Repair Manual M28 SKYTRUCK 2014

POLSKIE ZAKŁADY LOTNICZE
Spółka z ograniczoną odpowiedzialnością w Mielcu

POLAND
Sign. No. M28/1/2001

Technical information contained
in this document was approved
based on Design Organization
Approval No. EASA.21J.112
REPAIR MANUAL
PZL M28
with PT6A - 65B engines
Revision No. 15
WARNING
THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICHIS PROPRIETARY, IS THE PROPERTY OF POLSKIE ZAKLADY
LOTNICZE SP. Z O.O., IS AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT
IT IS NOT TO BE USED, DISCLOSED, OR REPRODUCED, IN WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR
MANUFACTURE FOR ANYONE OTHER THAN POLSKIE ZAKLADY LOTNICZE SP. ZO.O. WITHOUT ITS WRITTEN CONSENT, AND THAT
NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED THEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE
LAW MAY RESULT IN CIVIL AND CRIMINAL PENALTIES.
EXPORT WARNING
THIS DOCUMENT CONTAINS TECHNICAL DATA THE EXPORT OF WHICH IS RESTRICTED BY EAR. DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED. PROPER
AUTHORIZATION IS REGQUIRED PRIOR TO PROVIDING THIS TECHNICAL DATA TO ANY OTHER COMPANY, ENTITY, PERSON, OR DESTINATION.
THIS DOCUMENT CONTAINS TECHNICAL DATA WHICH MIGHT BE ALSO SUBJECT TO POLISH OR EUROPEAN LAW AND NEED AUTHORIZATION FROM POLISH
GOVERNMENT PRIOR PROVIDING THIS TECHNICAL DATA TO ANY OTHER COMPANY, ENTITY, PERSON, OR DESTINATION.
This Document contains technical data subject to:

1. Export Administration Regulations (EAR), 15 C.F.R. parts 730 – 774. Yes No
2. Council Regulation (EC) No 428/2009 of 5 May 2009 setting up a Community regime
for the control of exports, transfer, brokering and transit of dual-use items.
Yes No
MIELEC
2001
REPAIR MANUAL
PZL M28
WITH PT6A-65B ENGINES
Polskie Zakłady Lotnicze sp. z o.o.

ul. Wojska Polskiego 3
39-300 Mielec, POLAND
e-mail: pzl@pzlmielec.com.pl
www.pzlmielec.com.pl
WARNING
Spraying primer or standing primed surfaces may result in release of hexavalent chromium.
Inhalation of hexavalent chromium dusts may cause lung cancer. Exposures are dependent
of factors including work practices and task duration. Use appropriate personal protective
equipment, including a respirator, when performing this work.
EXPORT CONTROL CLASSIFICATION
1. U.S.: ECCN (EAR) 9E991

2. PL/UE: ECCN 9E999
Revision 9
M28
REPAIR MANUAL
CONTENTS
SECTION I. TYPICAL REPAIRS
SECTION II. MATERIALS USED FOR REPAIR
SECTION III. REPAIR CONNECTIONS
SECTION IV. SERVICE LIFE
WARNING
Spraying primer or standing primed surfaces may result in release of hexavalent
chromium. Inhalation of hexavalent chromium dusts may cause lung cancer. Exposures
are dependent of factors including work practices and task duration. Use appropriate
personal protective equipment, including a respirator, when performing this work.
NOTE
If it is not feasible to make a repair and it is necessary to perform a flight with unrepaired
damage, turn to the repair project author (DOA PZL) to apply for an analysis if it is
allowable to perform such a flight with unrepaired damage and to issue an appropriate
statement.
Revision 9 Contents 1/1

M28
REPAIR MANUAL
LOG OF REVISIONS
REVISION NO.
REVISED PAGES AND SECTIONS DESCRIPTION OF REVISION DATE
CODE
1 Document, Assy. Repair Manual Incorporation. January
21482 17, 2002
2 Log of Revision – p. 1; Procedure of sealing the fuel tanks October
22843 List of Valid Pages – p. 1, 2; complemented; English unit's 10, 2003
Section 1 – p. Contents, incorporated.
p. 1-1 to 1-15, 1-21, 1-23, 1-27
to 1-31,1-33 to 1-37, 1-40, 1-41,
1-43;
Section 2 – p. 2-1 to 2-3, 2-5, 2-
7, 2-12 to 2-17;
Section 3 – p. Contents, p. 3-41
to 3-48;
Section 4 – p. 4-2.
3 Log of Revision – p. 1; Added substitutes of the rubber October
29175 List of Valid Pages – p. 1, 2; hoses. 24, 2008
Section 4 – p. Contents 1,
p. 4-2, 4-3.
4 Log of Revision – p. 1; Procedure of additional sealing February
32215 List of Valid Pages – p. 1, 2; of internal fuel tanks by installing 09, 2011
Section 1 – p. Contents 1, cover plates (straps) has been
p. 1-4, 1-4a. canceled.
5 Log of Revision – p. 1; Remove and reworded the section May
33443 List of Valid Pages – p. 1, 2; 1; Remove incorrect numbers of the 21, 2012
Section 1 – p. Contents 1, 2, rubber hoses.
p. 1-1 to 1-79;
Section 4 – p. 3.
5A Log of Revision – p. 1; Introduced the change of editorial. May
33476 List of Valid Pages – p. 1; 28, 2012
Section 1 – p. 1-48, 1-49.
6 Title Page – p. 2; Introduced a warning about harmful August
33844 Log of Revision – p. 1; action of the primer for the health. 16, 2012
List of Valid Pages – p. 1;
Contents – p. 1;
Section 1 – p. 1-1, 1-70.
7 Log of Revision – p. 1; Introduced attention about the September
33927 List of Valid Pages – p. 1; thickness of paint coating. 17, 2012
Section 1 – p. 1-73.
8 Log of Revision – p. 1; Incorporated a note on a procedure April
35088 List of Valid Pages – p. 1; when it is necessary to perform 25, 2013
Contents – p. 1. a flight with unrepaired damage
to a service station.
9 Title Page – p. 1, 2; Introduced a procedure repair May
35115 Contents – p. 1; of single parachute seat and 09, 2013
Log of Revision – p. 1; replacement of seals on the tail
List of Valid Pages – p. 1, 2; plane and its slats, corrected editing
Section 1 – p. Contents 1, 2, errors.
p. 1-51 to 1-88.
10 Log of Revision – p. 1; Introduced information about repair September
35529 List of Valid Pages – s. 1; the electrical wires, 17, 2013
Section 1 – p. 1/2, 2/2, 7, from Add information about use US
48 to 147; hardware for repair in secondary
Section 2 – p. 1; structure;
Add information about use 8681HS
patches;
11 Log of Revision – p. 1; Actualized information about December
35989 List of Valid Pages – s. 1; ailerons balance 09, 2013
Section 1 – p. 63
Revision 13 Log of Revisions 1/2
M28
REPAIR MANUAL
LOG OF REVISIONS
REVISION NO.
REVISED PAGES AND SECTIONS DESCRIPTION OF REVISION DATE
CODE
12 Log of Revision – p. 2; - Introduced the substitute December
36035/DB List of Valid Pages – p. 1; of glue. 16, 2013
Section 1 – p. 3, 46, 47.
13 Log of Revision – p. 1, 2; - A note was added on using January
36072/DB List of Valid Pages – p. 1; alternative methods approved by 14, 2014
Section 1 – p. 8; 41a, 41b, 42, the Supervisory Office while
43. draining the containers for the
repair of the wing in the areas of
integral fuel containers;
- There was introduced a method of
repair of collar crack of oil cooler
tunnel in the lower engine
cowling.
14 Log of Revision – p. 2; - There was corrected the text February
36264/DB List of Valid Pages – p. 1; concerning the description of 13, 2014
Section 1 – p. 70. corrosion depth.
15 Title page – p. 1; - Supplemented front page informs May 25,
38084/DB Log of Revision – p. 2; that this technical information 2015
List of Valid Pages – p. 1. contained in this document was
approved based on Design
Organization Approval
No. EASA.21J.112.
LOG OF REVISIONS – 2/2 Revision 15

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REPAIR MANUAL
SECTION I
TYPICAL REPAIRS
CONTENTS
PAGE
1. AIRFRAME STRUCTURE REPAIR ............................................................................... 1-1
1.1 TROUBLESHOOTING ................................................................................................. 1-1
1.2 CLASSIFICATION OF DAMAGE................................................................................ 1-2
1.3 PREPARATION FOR REPAIR.................................................................................... 1-7
A. PREPARATION FOR ALUMINUM ALLOY STRUCTURE RIVET REPAIR ..... 1-7
B. PREPARATION FOR WING REPAIR IN INTEGRAL FUEL TANK AREA ...... 1-8
1.4 SEALING OF FUEL TANKS ....................................................................................... 1-9
1.5 REPAIR OF ALUMINUM ALLOY STRUCTURE – GENERAL PRINCIPLE ......... 1-11
A. REMOVAL OF SKIN SCORES AND SCRATCHES ........................................ 1-11
B. REMOVAL OF SKIN CRACKS, PUNCTURES AND CORROSION ............... 1-12
C. TYPICAL REPAIR OF THE WING NOSE SURFACES
AND SLATS SURFACES .................................................................................. 1-19
D. TYPICAL REPAIR OF REMOVABLE VERTICAL FIN NOSE AND SKIN
ON THE HORIZONTAL STABILIZER DEFLECTOR (FENCE) .................... 1-19
E. TYPICAL REPAIRS ENGINE COWLINGS AND OTHERS ELEMENTS
OF SECONDARY STRUCTURE ...................................................................... 1-20
1.6. REPAIR OF EXHAUST PIPES ............................................................................. 1-45
1.7. REPAIR OF PARTS OF GLASS LAMINATES.................................................... 1-46
A. REMOVING SCRATCHES, CRACKS .......................................................... 1-46
B. REMOVING OF DELAMINATION (CURLS) ................................................ 1-47
C. REPAIR OF DELAMINATION ON THE EYEHOLE COVER EDGES.......... 1-47
1.8. REPAIR OF THE OTHER ELEMENTS OF THE AIRPLANE .............................. 1-48
A. DAMAGE OF THE SKIN (UPHOLSTERY)
OF THE SINGLE PARACHUTE SEAT ......................................................... 1-48
2. LANDING GEAR REPAIR ........................................................................................... 1-51

2.1. REPLACEMENT OF THE LANDING GEAR WHEEL BEARINGS ..................... 1-53
A. REPLACEMENT OF THE MAIN WHEEL BEARINGS ................................ 1-53
B. REPLACEMENT OF THE NOSE WHEEL BEARINGS ............................... 1-59
3. CONTROL SURFACES BALANCE ................................................................................. 1-63

A. AILERONS BALANCE....................................................................................... 1-63
B. ELEVATOR BALANCE ..................................................................................... 1-65
C. RUDDER BALANCE .......................................................................................... 1-67
4. CORROSION REMOVAL AND PREVENTION................................................................ 1-69

4.1. GENERAL .................................................................................................................. 1-69
4.2. REMOVAL OF CORROSION .................................................................................... 1-71
A. SURFACE CORROSION ON ALUMINUM ALLOY PARTS ............................ 1-71
B. INTER-PLY CORROSION ON ALUMINUM ALLOY PARTS .......................... 1-71
C. CORROSION ON MAGNESIUM ALLOY PARTS ............................................ 1-71
D. CORROSION ON STEEL PARTS ..................................................................... 1-72
Revision 10 Contents 1/2

M28
REPAIR MANUAL
SECTION I
TYPICAL REPAIRS
CONTENTS (CONT.)
PAGE
5. REFURBISHING OF LACQUER COATING REPLACEMENT OF SEALS ............... 1-73
5.1. PREPARATION OF SURFACE TO BE PAINTED .............................................. 1-73
5.2. REFURBISHING OF LACQUER COATING ON OUTSIDE METAL SKINS....... 1-74
5.3. REFURBISHING OF LANDING GEAR LACQUER COATING ........................... 1-76
5.4. REFURBISHING OF LACQUER COATING ON PARTS INSTALLED
INSIDE AIRFRAME AND ITS INTERIOR SURFACES ....................................... 1-76
5.5. REFURBISHING OF LACQUER COATING ON BOLT HEADS
AND PROTRUDING BOLT PARTS WITH NUTS................................................ 1-77
5.6. REFURBISHING OF FUSELAGE NOSE RADIO-TRANSPARENT LACQUER
COATING (APPLIES TO INTERNAL AND EXTERNAL SURFACE) ................. 1-77
5.7. REFURBISHING OF LACQUER COATING LAMINATE PARTS ....................... 1-78
5.8. REMOVING OF TEMPORARY MARKS ADHESIVE FOIL ................................. 1-79
6. REPLACEMENT OF SEALS ....................................................................................... 1-81

6.1. REPLACEMENT OF SEALS ON HORIZONTAL STABILIZER
AND ITS DEFLECTORS ...................................................................................... 1-81
7. REPAIR OF ELECTRICAL SYSTEM. GENERAL INFORMATION ........................... 1-87

7.0. BASIC INFORMATION CONCERNING ELECTRICAL
SYSTEM AND ITS REPAIRS ............................................................................... 1-87
7.1. WIRES ................................................................................................................... 1-87
7.2. UNITS, ELECTRICAL CONNECTORS, CONNECTING
BLOCKS, CONNECTORS OF UNITS AND COMPONENTS ............................. 1-94
7.3. POWER DISTRIBUTOR BOXES ......................................................................... 1-99
A. TYPICAL REPAIR PROCEDURES (EXAMPLE) ......................................... 1-99
B. TYPICAL TABLE OF CONNECTIONS – EXAMPLE ................................. 1-102
C. TYPICAL CONNECTIONS AND TERMINALS........................................... 1-103
Contents 2/2 Revision 10

M28
REPAIR MANUAL
SECTION I. TYPICAL REPAIRS
1. AIRFRAME STRUCTURE REPAIR
1.1. TROUBLESHOOTING
In order to determine condition and extent of damage to airplane structure elements, first
clean and inspect. Damage to the airplane may be caused by impact, wear, or parts
malfunctioning. Impact damage will vary with the force and location of impact and the type of
object causing the damage. During inspection of the damaged area note original damage is
often transferred from one element to another bringing about deformation or distortion. Non-
typical stress due to a strike or impact to a rib, frame or similar element may be transferred to the
ends of structural elements bringing about secondary damage such as sheared or stressed rivets,
elongated holes under bolts or corrugated skin. The attachment points should be carefully
inspected for signs of deformation and security of attachment in the region of the original and
secondary damage.
Wear can be attributed to normal usage and/or misalignment of movable surfaces. Parts
can be destroyed by chaffing, or may malfunction as a result of fatigue, corrosion, overstress,
or previously undetected damage. Damage not caused by impact must be evaluated and
corrected to prevent recurrence. This may require reinforcement of the structure or additional
actions; for example corrosion prevention measures. Increased inspections and periodic
maintenance may also be required. Each part in the damaged area must be inspected and the
amount of damage determined and classified.
Structural repairs described in this section are intended for use in conjunction with
general aircraft maintenance repair procedures.
NOTE
Line Level Maintenance repair is limited to minor repair of sheet metal cracks,
scratches, corrosion, and loose or missing hardware. These repairs can be
accomplished using the airframe repairer’s toolkit and portable hand tools. If any
extensive damage occurs or major repair is required, repairs shall be
accomplished by an Approved Maintenance (Repair) Organization or next higher
maintenance level as required by special repair procedure approved by
manufacturer or local Aviation Authority.
WARNING

are dependent of factors including work practices and task duration. Use appropriate
Revision 6 1-1
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REPAIR MANUAL
1.2. CLASSIFICATION OF DAMAGE
After inspection, Each incidence of damage must be classified into one of 3 categories:
- negligible (slight);
- repairable;
- requiring replacement.
Division into these categories is designed to facilitate the mechanic’s ability to evaluate the
extent and critical values of the damage. Of course, common sense should be used when
classifying damage, as damage may be meet the criteria for more than one category:
1. Negligible damage is damage which will have little or no effect on the airworthiness
of the part or area, and may be ignored or corrected by a simple repair, such as: removal of
dents, (blending) evening-up of scratches, or stop-drilling cracks to non-structural elements and
removal of corrosion or touch-up of protective finish on parts.. Examples of such damage are:
slight dents without cracks, abrasions or sharp edges, or waviness due to stresses and without
infringement on other interior structure. Stop-drilling cracks is considered a temporary repair until
such time a more permanent repair can be affected.
NOTE
Damageto any of the following areas cannot be classified as Negligible:
- Damage in the region of the integral fuel tanks.

Damage in this area should undergo more thorough analysis as
thestructuer in this region is subject to flight loads and the loads due to fuel
pressure. All cracks, abrasions and dents should be carefully repaired to
eliminate possible fuel leaks due to the crack or any possible propagation
of the crack,
- Cracks at the control surface attachment fittings or the supporting structure.

These cracks may not be treated as negligible. Damaged parts should be
replaced or repaired in accordance with the special repair procedure .
Damage to control surfaces other than cracks to fittings and support
structure may be implemented in accordance with procedures for other
elements of the airframe structure.
- Damage to primary structure of the fuselage, box wings and vertical fin
and horizontal stabilator.
- Damage to structural parts of the landing gear bracket (console). These

may not be treated as negligible. Repair or replace affected parts.
2. Reparable damage is such that the damage may have an effect on airworthiness ue
to loss of functionality of a given element, or on the general condition of the component part.
Damage may be corrected by installing a doubler, a patch or inserting a piece of material.
Examples of such damage are dents, scratches or punctures to the skin requiring
installation of doublers and damage to longerons and frames beyond the definition of a negligible
damage, and which have been deformed or twisted to a degree not requiring excessive
remoulding or restoring of the original shape.
Reparable cracks, scratches, nicks or gouges are stop-drilled using a 1/8-inch-diameter
drill and patched. Punctures, deep dents, and corroded areas of skin and webs are trimmed
out and patched. Smooth dents should be tapped out using a soft mallet and the area
reinforced with stiffening angles.
1-2 Revision 5
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REPAIR MANUAL
NOTE
Damage to a structural component shown in the Maintenance Manual
should be evaluated for possible repair or replacement at a higher level of
maintenance, but the repair or replacement procedure should be approved
by manufacturer or locally Aviation Authority. If negligible damage limits are
exceed.
3. Damage requiring replacement is damage that may have an effect on airworthiness

due to loss of functionality of a given element, or may have an effect on the general condition of
a component part, however, repair by installing a cover plate or patch is not practical or is
prohibited.
Examples of such damage are assemblies which have been twisted or buckled beyond
the allowable values, parts with extensive corrosion damage, or damage in which the repair
requires the use of tools or instruments inaccessible in a repair workshop, or repairs which are
difficult to perform in a field repair shop.
Small doublers, splices, clips, brackets, and short stiffening members, damaged beyond
negligible limits, are usually replaced because repair of these members is impracticable.
Some highly stressed structural members cannot be repaired without reducing the established
margin of safety for the structure. Such members, when damaged beyond negligible limits,
must be replaced. Sometimes, where damaged members have a shape which is difficult to
repair, it may be better, in view of man-hours and cost, to replace the damaged member rather
than attempt a repair. Replacement members shall be made with the same type material (or
substitute) and temper as the original member and are installed using the same type fasteners
(or substitute).
Damage to a removed structural component should be evaluated for possible repair at a

higher level of maintenance according to special replacement procedure approval by
manufacturer or locally Aviation Authority.
It is import when evaluating and classifying damage, to determine if the damage is to

primary or secondary structure. The primary and secondary structure of the airplane is defined
in respective chapters of the Maintenance Manual.
In cases of uncertainty as to the classification of damage, the aircraft manufacturer

should be contacted with a description and location of damage.
Revision 12 1-3
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1.2.1. DAMAGE LIMITATIONS
1.2.1.1. Airplane structure
A. Negligible damage limitations
1. Skin scores, and scratches not over deep:
Fuselage: to 0,2 mm (0.008 in) for the skin to 0,8 mm (0.031 in) and,
to 0,3 mm (0.012 in) for the skin 1,2 mm (0.047 in);
Wing
with control
surfaces: the same as for fuselage;
Wing strut: the same as for fuselage;
Empenage
and control
surfaces : to 0,1 mm (0.004 in) on stabilator and fin skin ;
2. Dents:
Fuselage: Skin dents not exceeding a h/l factor 0.04, where: h = depth of
dent, and l = length of dent;
Wing
with control
surfaces: Skin dents not exceeding 1 mm (0.04 in) deep on nose part of the
wing
Wing strut: the same as for fuselage;
Empenage
and control
surfaces : Skin dents not exceeding 3 mm (0,12 in) deep and 55 cm2 on
nose fin and stabilator deflector skin and lower end of vertical fin.
3. Skin corrosion up to 0,1 mm (0.004 in) deep;

4. Weakened rivets - max. 5 % in riveted join.
5. Negligible damage limitations for primary main frame elements (for definition primary
main frame -see M28 05 Maintenance Manual)
NOTE
No damage on primary structure of the fuselage, wing and empennage may
be classified as negligible excluding scores, dents and scratches or corrosion
not over 0,1 mm (0.004 in) deep. When damage limits, are exceeded, or if the
damage is in the area that requires engineering contact the aircraft
manufacturer in writing with a description of the damage.
1-4 Revision 5
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B. Repairable damage limitations:
NOTE
When damage limits, are exceeded, the responsible maintenance
organization should contact the aircraft manufacturer in writing with
a description of the damage.
1. Skin scores, dents and scratches not over deep:
Fuselage: over 0,2 mm (0.008 in) for skin up to 0,8 mm (0.031 in) thick and;
over 0,3 mm (0.012 in) for skin up to 1,2 mm (0.047 in) thick without
limitation of length.
Wing with
control
surfaces: the same as for fuselage excluding areas of the torsion boxes
(integral fuel tank areas). Repairs in the fuel tank area are to be in
accordance with paragraph1.4.
Damage on the aluminum alloy skin of the wing flaps and ailerons not
exceeding 0,1 mm (0.004 in) in depth and 250 mm (10 in) in total
length.
Wing strut: the same as for fuselage.
Empennage: over 0,1 mm (0.004 in) to 0,2 mm (0.008 in) deep and up to 150 mm
in length on nose skin of the stabilator and fin. Maximum area of the
doubler is 100 cm2(15.5 sq.in) . Maximum amount of the doublers = 3
and 1 between ribs.
2. Cracks and punctures of skin:
Fuselage: Cracks and punctures of skin, up to 80 mm in length. Cracks not to

extend to attaching holes.
Wings: the same as for fuselage excluding areas of the torsion boxes
(integral fuel tank areas). Repairs in the fuel tank area are to be in
accordance with paragraph 1.4.
Wing strut: the same as for fuselage
Empennage: the same as for fuselage excluding areas of the torsion boxes
3. Skin dents with the h/l factor above 0.04 and maximum dimensions 200X200 mm (8
inX8 in), where h = depth of dent, and l = length of dent;
4. Skin corrosion above 0,1 mm (0.004 in) deep;
5. Weakened rivets - max. 10 % in riveted join.
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1.2.1.2 Damage limitations for trim tab:
A. Acceptable damage (not resulting in the operation hold up) (Negligible

damage):
• Local dent of a up to 1 mm deep;

• Minor crack up to 25 mm (drill 2.0 mm dia holes at the ends of the crack);
• Corrugation of the skin not deforming the hinges (after disconnection of the
control system push rods from the trim tab, the tab deflects freely, with no
jamming);
• Damage to the lacquer coating (touch up paint coatings);
B. Damage qualifying the trim tab for replacement:
• Skin crack exceeding 25 mm;

• Skin corrugation deforming the hinges (after disconnection of the control
system push rods from the trim tab, the tab deflects with jamming);
• Damage to the hinges;
NOTE
Others repairs of these trim tab are impracticable
1.2.1.3 Damage limitations for other elements of the secondary structure of the
airplane:
1. Cargo door.
A. Acceptable damage (Negligible damage).
A.1. Since the cargo door are not load carry-through structure, minor scratches and dents
of any length and thickness are acceptable on their surface, provided there are not
cuts (cracks) through. It is allowable not to make repairs of these minor scratches
and dents. However, if feasible, bring the dent surfaces, whenever possible, to the
proper door cover contour (dress and lute), and then refurbish the paint coating in
accordance with the M28 Airplane Repair Manual, Section I, Para. 5.
A.2. Inspect the Cargo door structure after removal of the cloth patches. After inspection,
bond the cloth covering the inspection openings using a market available
nitrocellulose adhesive providing the appropriate bond quality. Replacement patches
can be made from any type of aviation cloth, provided that proper bonding and
adherence are achieved (unsticking of the cloth is unacceptable). After bonding,
stretch the cloth applying a coat of Nitrocel (agent used for stretching the aviation
cloth).
NOTE
Type of cloth and adhesive is the same as for all cloth hole plugs
used on the airplane structure.
2. Exhaust pipes - see paragraph 1.6.
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REPAIR MANUAL
1.3. PREPARATION FOR REPAIR
Before repair, position the aircraft in a convenient place so that it can remain
undisturbed for the duration of the repair. If however, the necessity arises to relocate the
aircraft,, the airplane is to be lifted using jacks and leveled.
NOTE
The use of US hardware for repair in secondary structure is allowable,
provided it is used in acc. to US standards (ex. industry or AC43.13) , for
providing sufficient strength, dimensions and type of protective coating. Holes
may be oversized to allow installation of nearest comparable hardware.
A. PREPARATION FOR ALUMINUM ALLOY STRUCTURE RIVET REPAIR
In order to prepare the area to be repaired, check and classify the nature of damage.
The thorough inspection shall be performed prior to repair. In some cases the damaged part can
be first classified as being subject to replacement; however a more accurate analysis after its
removal from the aircraft may indicate that the affected part can be repaired.
NOTE
After a thorough investigation of damage, a course of action should be
taken to restore damaged area to its original condition. Clean out
damaged area first. Take care to prevent further damage during this
operation. The following procedure for cleaning out a damaged area
applies to all types of damage except where noted for specific
construction..
1. Restore all dented skin and supporting structure to its original shape and condition
wherever possible.
2. Cut away all jagged edges and severely distorted material, removing enough material
to eliminate any radiating cracks. When cutting out the affected section, trim the edges
parallel or perpendicular to the edge of the specific part.
3. Leave as much radius as possible in corners of cutouts. Smooth out all edges.
4. Round out holes in flat or contoured sheets to form a smooth outline.
5. Smooth scratches and dents If nicks or abrasions are greater than negligible
limitations, they should be treated as cracks and prepared for patching.
6. Do not leave isolated cracks unattended even though area is considered non-
stressed. Stop-drill crack using a 1/8-inch diameter drill.
7. To recondition the original paint and anti-corrosion protection coating, paint the affected
area.
NOTE
If the damage is adjacent to previously repaired section, cut out this
section and repair it anew together with the neighboring affected area.
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B. PREPARATION FOR WING REPAIR IN INTEGRAL FUEL TANK AREA
Drain fuel from fuel tanks before proceeding to any preservation work in the region of
fuel tanks.
NOTE
While conducting servicing work associated with the fuel system, fire
protection equipment must be available nearby.
Prior to the preservation of the fuel system, the aircraft must be
grounded.
Avoid evaporation of fuel left in the disconnected fuel lines. Such an
accumulation of fuel vapors might cause hazard of explosion.
Make sure that the master switch is OFF while the work is done in the
fuel system, unless otherwise specified.
1. Empty the fuel tanks with the power supply system ON in the following way:
- place the fuel drip pan or container,
- ground the aircraft and container.
a) centerwing tanks:
- connect the fuel drain line to the drain valves (one after another) in the
lower wing skin and drain fuel;
b) outer wing tanks:
- connect the fuel drain line to the fuel filter drain valve in the engine nacelle;
- open three 1 seq. fire valve;
- turn ON the electric fuel pump and drain fuel through the fuel filter drain
valve;
- turn OFF the pump, close the valves and disconnect the fuel drain line.
2. Before repair, dry the tank with inert gas (argon or carbon dioxide) to prevent from
possible explosion:
- open the fuel filler and insert the inert gas supply line into the tank;
- release gas into the tank for aminimum of ten minutes to remove all the fuel
vapors. Argon and carbon dioxide are heavier than air, so they remain in the tank
for the time of repair.
NOTE
The use of fuel cell blowers in an approved alternate method.
3. After completing the servicing work, clean the repaired area thoroughly with clean cloth
moistened in acetone or similar solvent. Bear in mind to pour the solvent onto the cloth
so as not to contaminate it. It is not allowed to use dirty solvent. Prevent the solvent
from dripping from the cloth.
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REPAIR MANUAL
1.4. SEALING OF FUEL TANKS
Sealing of the integral fuel tanks inner surfaces
During the course of the work with leak stoppers and adhesives, safety and fire protection
precautions should be strictly observed.
Lights to include flashlights, lamps and lanterns, used in fuel

systems repair facilities/areas shall be intrinsically-safe (non-
explosive).
Only persons specially trained in industrial safety precautions are

allowed to work with adhesives and leak stoppers.
All work should be performed by personnel dressed in protective

cotton clothes and rubber gloves. After the work has been finished
wash hands with soap and water.
The containers and tools used during sealing are to be cleaned

with solvent and acetone.
- Determine precise location of every fuel leak.
- Drain fuel from the tanks.
- Position hydraulic jacks under the airplane jack (support) points and, if the centerwing
tank lids are to be removed, position additionally adjustable stop chocks under the engine mount
frames.
- Remove the tank lids in the centerwing or outboard wing upper section, as required.
- Dry and clean thoroughly the fuel tank interior, and remove old leak stopper from the
leaking area.
- Carefully clean the area subject to sealing; use a vacuum cleaner, a bristle brush and
a piece of rag.
- De-grease the surface being sealed using solvent HN-Cleaner SPB or substitute, and
then acetone. Use cotton-cloth rag (lint-free).
NOTE
After the surface has been cleaned and de-greased, DO NOT touch the
area with your hands.
- Prepare leak-stopper following the instructions on the package.
NOTE
Only U30MES-5 or PR-1782 leak stoppe rmay be used to repair internal
surfaces of the fuel tanks . Do not use another leak stopper for this
purpose.
It is allowable to use another PR leak stopper but only to seal the cover
connection with the wing structure.
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REPAIR MANUAL
- Apply a uniform layer of the leak-stopper upon the prepared surface; use a short-
bristle paint brush.
- With the leak-stopper hardened, carefully clean the fuel tank's interior.
- Install the tank lids on the wing upper surface; check for proper attachment
(connection torque-tightening) and for condition of the lid seals.
- Remove the supports, stop chocks and hydraulic jacks.
- Visually Inspect the fuel tank for leak-stopping coverage. Apply a coat of chalk
compound on the carefully-cleaned exterior surfaces of the wing bottom in the region being
sealed. Fill the tank in accordance with the manual. After 30 minutes visually inspect for leaks. No
leaks are allowable.
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REPAIR MANUAL
1.5. REPAIR OF ALUMINUM ALLOY STRUCTURE – GENERAL PRINCIPLES
A. REMOVAL OF SKIN SCORES AND SCRATCHES
a) Skin damage 0.2 mm (0.008 in) through 0.3 mm (0.012 in) deep (for skin 0.6
mm [0.024 in] and 0.8 mm [0.031 in] thick) and 0.3 mm (0.012 in) through 0.5 mm (0.020 in)
(for skin 1.2 mm [0.047 in] thick) and up to 130 mm (5.1 in) long.
1. Drill the ends of the damage with a 3.0 mm (0.12 in) diameter drill.
2. Blunt the sharp edges of the damage with a round steel pin.
3. Cut out and match a cover plate (1) (Fig. I-1) of 2024-T4 or 2024-T3 anodized
sheet metal, so that the distance from the end of the damage to the edge of the
cover plate is not less than 40 mm (1.6 in). The thickness of the cover plate
material should not exceed the thickness of the material being repaired by more
than 20%.
Thickness, basic skin, mm (in) 0.6 (0.024) 0.8 (0.031) 1.2 (0.047)
Thickness, cover plate, mm (in) 0.8 (0.031) 1.0 (0.039) 1.5 (0.059)
4. Define and drill the holes under rivets in the cover plate and in the skin. Use the
old holes to define the necessary holes.
5. Repair the connections, deburr the hole edges in the skin and the cover plate.
Make the connection around the contour of the cover plate.
6. Clean the parts removing the filings and dirt with a hair brush and a piece of cloth.
7. Place the cover plate over the skin, on the control screws, rivet and paint.
Fig. I-1. Repair of skin panel damage up to 0.3 mm (0.012 in) deep (for skin 0.6 and 0.8
mm [0.024 in and 0.031 in] thick) and up to 0.5 mm (0.020 in) deep (for skin 1.2
mm [0.047 in] thick) and 130 mm (5.1 in) long.
1-Cover Plate; 2-Rivet of 3.5 mm (0.14 in) dia. (for center fuselage section in the area of Frames
No. 13 to 15) and of 3.0 mm (0.12 in) dia. (for the remaining fuselage sections).
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REPAIR MANUAL
b) Skin damage over 0.3 mm (0.012 in) deep (for the skin 0.6 and 0.8 mm (0.024
and 0.031 in) thick) and over 0.5 mm (0.020 in) deep (for the skin 1.2 mm (0.047 in) thick)
and up to 130 mm (5.1 in) long.
Repair the damage by riveting a cover plate (1) (Fig. I-2) as specified under items
a(1) through (7), in addition, rivets should be installed in the middle of the cover plate and around
the damage.
c) Skin damage over 0.2 mm (0.008 in) deep (for the skin 0.6 and 0.8 mm (0.024
and 0.031 in) thick) and over 0.3 mm (0.012 in) deep (for the skin 1.2 mm (0.047 in) thick)
and over 130 mm (5.1 in) long.
Replace the whole skin or a part of it and the structural elements.
B. REMOVAL OF SKIN CRACKS, PUNCTURES AND CORROSION
a) Skin cracks, and punctures up to 80 m (3.15 in) large.
1. Cut out a circle or an oval at the damaged place and clean the edges of the
cut-out (Fig. I-3).
2. Cut out a cover plate using 2024-T4 or 2024-T3 anodized metal sheet. The
dimensions - as required depending on the size of the damage. At a minimum cover plate
thickness should be 20% larger than the thickness of the skin material being repaired.
3. Install the cover plate on the PR 1422B-2 leak stopper.
NOTE
When installing a cover plate inside the fuselage install the cover plate
of the same material as the cut-out place.
4. Rivet the cover plate.
5. When the skin is punctured and the longeron damaged; cut out the damaged
section, place the insert (2) (Fig. I-4) (of the thickness equal to the thickness of the skin) and the
profile (4) of the same section as the longeron. Install the cover plate (1).
NOTE
In case of glue-welded joints do not cut out the level longeron web. The
connection of longerons to be made in accordance with the type
"longeron into longeron".
6. When the skin is punctured and the frame ring damaged: cut out the damaged
frame ring, install a reinforcing cover plate (1) (Fig. I-5) of the thickness equal to the ring
thickness. Repair the skin.
NOTE
Cover plates are made of 2024-T4 or 2024-T3 material. Bend radius of
the webs is R = min. 3 x cover plate thickness.
7. When the frame ring is damaged in the form of a crack (without damage to the
fuselage skin):
- drill the end of the crack; rivet a cover plate (Fig. I-6).
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REPAIR MANUAL
b) Skin cracks and punctures over 80 mm (3.15 in) large
Replace the structural elements completely or partially.
c) Corrosion over 0.1 mm (0.004 in) deep
1. When corrosion is present, cut out the damaged skin section and install a new
one in accordance with items a(1) and (2).
2. When the corrosion is found on the longeron or frame ring, cut out the damaged
section and repair in accordance with items a(5) and (6) (without repair of the skin).
Fig. I-2. Repair of skin damage over 0.3 mm (0.012 in) deep (for the skin 0.6 and 0.8 mm
(0.024 in and 0.031 in) thick) and over 0.5 mm (0.020 in) deep (in the case of the
skin 1.2 mm (0.047 in) thick) and up to 130 mm (5.1 in) long.
No. 13 to 15) and of 3.0 mm (0.12 in) dia. (for the remaining fuselage sections); 3-Rivet of old
hole dia.
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Fig. I-3. Repair of punctured or cracked skin
No. 13 to 15) and of 3.0 mm (0.12 in) dia. (for the remaining fuselage sections);
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REPAIR MANUAL
Fig. I-4. Repair of punctured skin and with damaged longeron
1-Cover plate; 2-Insert; 3; 6 -Rivets of 3.5 mm (0.14 in) dia.(for skin thickness of 0.6 and 0.8 mm
(0.024 in and 0.031 in), of 3.0 mm (0.12 in) dia. (for skin thickness of 1.2 mm (0.047 in) thick), 4-
Profile; 5-Rivet of 3.5 mm (0.14 dia.)
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Fig. I-5. Repair of frame ring with damaged web

1-Cover plate of thickness (δ) equal to ring thickness; 2-Rivet of old hole dia.; 3-Rivet of 3.5 mm
(0.14 in) dia.
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REPAIR MANUAL
Fig. I-6. Repair of frame ring with damage over 0.2 mm (0.008 in) deep and over 5.0 mm
(0.2 in) long.
1-Cover plate of thickness (δ) equal to ring thickness;.; 2-Rivet of 3.5 mm (0.14 in) dia. 3-Rivet of
old hole dia.
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C. TYPICAL REPAIR OF THE WING NOSE SURFACES AND SLATS SURFACES
1. Remove the scratches with a scraper, clean with abrasive paper and refurbish the
lacquer coating. If on the wing nose or slat surface is cracked or punctured, stop-drill holes at
the ends of the crack, paying attention not to penetrate with the drill when drilling a slat and
not to damage the inner stiffening of the skin. The damaged section of the wing nose skin may
be cut out, if necessary.
2. Cut out a cover plate of 2024-T4 or 2024-T3 anodized metal sheet 0.6 mm (0.024
in) thick. The cover plate dimensions should provide for distance from a damage end to the cover
plate edge not less than 25 mm (1 in) in every direction, bend it according to the contour of the
nose, coat with the epoxy primer (epoxy paint yellow chromium for priming) with 1.5% of
aluminum powder. The edges of the cover plate to be filed askew and the corners rounded.
3. Open the deflectable panels.
4. Install a reinforcing cover plate on the inside surface of the skin - drill the holes under
the rivets (the pitch 25 mm (1 in)). If possible, use the old existing holes.
5. Rivet the cover plate with the countersunk rivets of 120° angle.
6. Apply one layer of the epoxy primer onto the formed rivet heads (epoxy paint yellow
chromium for priming).
7. Close the deflectable panels.
D. TYPICAL REPAIR OF REMOVABLE VERTICAL FIN NOSE AND SKIN ON THE

HORIZONTAL STABILIZER DEFLECTOR (FENCE).
Removal of scratches, scores, dents, cracks and punctures
1. Remove the nose (vertical fin) from the aircraft.
2. Remove the scratches with a scraper, clean with abrasive paper and refurbish the
lacquer coating. If the vertical fin nose is cracked or punctured, stop-drill at the ends of the
crack. The damaged section of the vertical fin nose skin may be cut out, if necessary.
3. Install the cover plate from inside:
- cut out a cover plate of 2024-T4 or 2024-T3 anodized metal sheet 0.6 mm (0.024
in) thick of the dimensions providing for distance from a damage end to the cover
plate edge not less than 25 mm (1 in) in every direction;
- blunt the edges of the cover plate and bend the cover plate matching it to contour
of the damaged place;
- coat the cover plate with the epoxy primer (epoxy paint yellow chromium for
priming) with 1.5% addition of the aluminum powder;
- rivet the cover plate onto the damaged place using the rivets of 3 mm (0.12 in)
diameter spaced every 20 mm (0.8 in). The existing holes should be used;
- apply the epoxy primer on the formed rivet heads (epoxy paint yellow chromium
for priming).
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REPAIR MANUAL
4. Reinstall the nose.
5. Where the cover plate can not be installed from inside, install it from outside.
NOTE
On the front part of the nose install an additional seam of dia 3.0 mm
(0.12 in) countersunk rivet of 90° angle (pitch 25 mm (1 in)). The holes
under the additional rivets to be drilled from the inside of the nose using
an elongated drill diameter 3.2 mm (0.126 in).
E. TYPICAL REPAIRS ENGINE COWLINGS AND OTHERS ELEMENTS OF

SECONDARY STRUCTURE
Most damages to the engine cowlings are damages on the deflectable cover hinge of
the removable engine cowlings and/or cracks of frames and skin. When the cover hinge is
damaged, the hinge should be replaced. Stop-drilling at the end of the cracks may be
temporarily used instead of replacement of the hinge, if the damage does not influence correct
and safe attachment and operation. When skin cracks occur, stop-drill or cut out the damage
area of skin and use a doubler. When the frame of the cowling is damaged, replace the frame
or part of the frame or make repair more simple method.
Examples of engine cowling repairs are given in paragraph 1.5.1. Example 7.
NOTE
For damages to other elements of the secondary structure not provided
in this chapter, perform repairs in accordance with methods given
above, choosing the optimal repair procedure.
Examples of repairs performed on aluminum structures
The examples shown concern a specific, actual damage and are in agreement with the
general rules of aluminum structure repairs shown above. The purpose of these
examples is to familiarize technical personnel with the types and procedures of
repairs. Selection of the best repair is left to the discretion of technician performing the
repair, taking into consideration the provisions and recommendations included in this
Section.
NOTES
1. The airplane aluminum structure repairs shown below can and
should be used when deciding the type of repair to be used for the
occurred damage. The same or similar damages in the shown
structural areas can be repaired in a similar way.
2. The Manufacturer or a local aviation authority should be consulted

on all repairs of the fuselage load-carrying through structure, wing
and empennage torsion boxes and landing gear bracket not shown
in this Section. In case of any doubts, always consult the
Manufacturer or a local aviation authority.
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REPAIR MANUAL
EXAMPLE 1: Repair of the wing nose surfaces (See paragraph C- Typical repairs of
the wing nose surfaces above)
I. Repair of the wing nose damage
Deflectable
panel
FWD
Cracked
skin of Rib no. 17
the wing
nose
Example 1. Figure 1. Bottom view on the RH wing damaged nose in area of rib no. 17
1. Prepare a strap of 2024-T4 or 2024-T3 anodized sheet metal of 0.5 or 0.6 mm

thickness in accordance with Example 1.Figure 2.
2. Cut out the damaged section of the nose skin.
3. Lay out and drill rivet holes.
4. Remove sharp edges, degrease the strap and the repaired area of the wing
nose skin.
5. Locate the strap on PR1422-B sealant and rivet it to the wing nose skin in
accordance with Example 1.Figure 2.
6. Degrease the repaired surface and apply epoxy primer of any type, for
example 7429-659-130, 830R or AERODUR CF PRIMER 3704.
7. Touch up paint coatings.
NOTE
Equivalent NAS rivets may be used in place of given rivet types.
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REPAIR MANUAL
Example 1. Figure 2. Repair of the wing nose damage
EXAMPLE 2: Repair of the wing slat
Cracked
skin of
the slat
Slat rib
Example 2.Figure 1. Bottom view on the RH wing damaged slat in area of rib no. 17
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REPAIR MANUAL
1. Analyze the damage and select a method for the slat repair. If there is a crack on the slat
surface, stop-drill stop the ends of the crack, paying attention not to penetrate with the drill
when drilling and not to damage the inner stiffening of the skin.
2. Prepare a strap of 2024-T4 or 2024-T3 anodized sheet metal of 0.6 or 0.8 mm thickness in
accordance with Example 2.Figure 2. In order to determine dimensions of the strap, begin
by determining the axis of the rivets on the slat rib. Then, through the existing rivets marked
as 1, 2 and 3 in Example 2.Figure 2, draw parallel axes to the rivet axis drawn (determined)
on the slat rib.
3. Determine locations of holes and size and dimensions of the strap.
4. Check the foam strip stiffening the slat edge for damage. If the strip is damaged, tear
it off along the damaged section and, having previously riveted the strap, make it up
by bonding the polyurethane foam on epoxy resin, and then cover it with glass cloth
(any type) and impregnate it also with epoxy resin.
5. Drill holes in the prepared strap in accordance with Example 2. Figure 2. Pay
attention to use 2.6X6-PA24-BN-70/1121-06 rivets or equivalents for riveting the
strap on the slat edge when the foam stiffening is torn off.
6. If the foam strip stiffening the slat edge is not damaged, attach the strap on the slat
edge using blind rivets. pulling them through the foam.
7. Remove sharp edges, degrease the strap and the repaired area of the slat nose skin.
8. Locate the strap on PR1422-B sealant and rivet it to the slat skin in accordance with
Example 2.Figure 2.
9. Degrease the repaired surface and apply epoxy primer of any type, for example
7429-659-130, 830R or AERODUR CF PRIMER 3704.
NOTE
Equivalent NAS rivets may be used in place of given rivet type .
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REPAIR MANUAL
Example 2.Figure 2. Two options for the slat repair
NOTE
It is recommended to use Option 2, since there is no detachment
of the skin from the rib.
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EXAMPLE 3. Repair of Skin on the Horizontal Stabilizer Deflector (Fence).
This damage in the form of dent and crack is shown in Example 3.Figure 1.
Existing rivets
Example 3.Figure 1. Location of horizontal stabilizer deflector damage
Repair the damaged skin area in accordance with the following procedure:
1. At the ends of the crack drill 2.0 mm (0.078 in) diameter holes.
2. Cut a strap (patch) out of 2024-T4 or 2024-T3 anodized sheet metal of 0.5 mm
(0.0196 in.) thickness and dimensions as shown in Example 3.Figure 2.
3. Determine location of the strap, lay out and drill 7 rivet holes in the strap and in the
skin in accordance with Example 3. Figure 2.
NOTE
Determine the rivet holes diameter upon selection of available blind rivets in
accordance with NAS1738B.
The rivet diameter should be within 3.0 to 4.0 mm (0.118 to 0.157 in) limits.
Select the rivet length per the stack up thickness which is 1.7 mm (0.067 in)
max.
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REPAIR MANUAL
Strap
Blind Rivets
2024-T4 or
2024-T3 ≠ 0,5
Crack
Existing rivets
Rib no. 2 axis
Example 3.Figure 2. Bottom view of the repaired surface of the deflector from the
horizontal stabilizer RH side.
4. Deburr the holes in the skin and in the strap. Degrease the skin and the strap
surfaces.
5. Locate the strap with PR1422-B sealant and rivet it to the skin with blind rivets.
6. Degrease the repaired surface and apply epoxy primer of any type, for example:
7429-659-130, 830R, or AERODUR CF PRIMER 3704.
7. Touch up paint as required.
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EXAMPLE 4: Repair of the Fin Skin.
A) Repair of the fin skin by the drilling crack and the overlay imposition.
LH fin inner side
Location of
damage
Stop drill of
the crack
Shape of the
strap
Additional rivet
Example 4. Fig. 1. Location of the LH fin upper inner side damage
Repair the damage skin surface as follows:
1. Prepare a strap of 2024-T4 or 2024-T3 anodized sheet metal of 0.4 mm thickness.

Adjust the strap dimensions in such a way as to obtain the rivet distance from the
strap edge of at least 7 mm.
2. Remove the existing rivets in location of the strap attachment.
3. At the crack end drill a 2.0 mm (0.078 in) hole.
NOTE
When drilling of this hole, pay attention not to damage the rib.
4. Locate and transfer drill the rivet holes in the strap.
NOTE
Determine the rivet holes diameter after selection of available
blind rivets in accordance with NAS1738B. The rivet diameter
should be within 3.0 – 4.0 mm (0.118 – 0.157 in).
5, Remove sharp edges, degrease the strap and the repaired area of the fin skin.
6. Locate the strap on PR1422-B Sealant and rivet it to the skin with the blind rivets.
7. Degrease the repaired area, apply epoxy primer and touch up the pain coating.
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B) Vertical stabilizer skin repair with external doubler (alternative).
a)
Location of
damage
Min radius
9,5 mm
Additional rivets
b)
Location of damage
Cut Line for damage

removal
Additional rivets
Corner rounded
Example 4. Fig. 2. Location of the LH fin upper inner side damage
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REPAIR MANUAL
REPAIR the damage skin surface as follows:
NOTE
When drilling care must be taken that no contact is made with underlying
skins and substructure
1. Remove the original fasteners in the repair area.
2. Slide a thin piece of metal between the damaged skin the substructure to protect the
structure during damage removal.
3. Remove the damaged area as shown in the drawing.
4. Minimum cut-out radius is 9,5 mm (0,375 in).
5. Manufacture filler or shims (whichever will be used) from the same material and
thickness as the original material. Use shims as needed to avoid abrupt transitions.
6. Manufacture doubler (strap) from same material as original, one gauge grater in
thickness.
7. Use the same size and type of fasteners as are used in the strongest fasteners
pattern in the repair area.
8. Use the same approximate rivet pitch as the original fasteners pattern or between 4D
and 12D.
9. Use row spacing of 75% to 100% of rivet pitch.
NOTE
Substitution of fasteners may be done on any equal strength basis (both
shear and tensile strength must be greater than, or equal to, the original),
and consideration must given to other properties, such as temperature
and corrosion resistance.
10. Cherrymax rivets or equivalent may be used, in place of solid rivets, where clearance
is restricted.
11. Maintain edge distance between 2D and 4D, with 2,5D preferred.
12. Deburr all holes and cutouts. Break all corners and edges. Doubler corners will have
a minimum radius of 9,5 mm (0,375 in).
13. Because of the nearly identical properties, 2024-T3 may be used as a substitute for
2024-T4.
14. Alodine and prime all parts.
15. Install parts when with sealant if appropriate for the area.
16. Paint to mach at earliest maintenance opportunity.
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REPAIR MANUAL
EXAMPLE 5: Repair of the vertical stabilizer nose
A) Damage of the front of the upper ribs LH vertical stabilizer in the form of cranks shown in
figure A.1. This is chafing at the top of LH vertical under the anti-collision light.
Location of
damage
Example 5. Figure A.1. Location of the rib damage
Repair the damaged rib as follows:
1. Prepare a new rib 28.00.3450.013.007 (without holes and mounted nut plates).
2. Cut out part of the rib from the new rib (about 100 mm from the leading edge) to used as
shown in figure A.2.
3. Remove the mounting rivets and four nut plates from the damaged rib.
4. Insert a new part of the rib to the damaged rib (from the bottom).
5. Drill holes for the nut plates in new part of the rib according to the holes in damaged rib.
6. Install four nut plates (2) with the rivets(3). Additionally install two rivets (3) and four
rivets (4) according to the Figure A2.
7. If required, blending and deburr outer surfaces of the damaged rib.
8. Degrease the repaired surface and apply epoxy primer of any type for example:
7429-659-130, 830R or AERODUR CF PRIMER 3704 as required .
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REPAIR MANUAL
3 (Additional rivet) Cut Line
A new
part of rib
3 (Additional rivet)
Example 5. Figure A.2. Prepare the rib for the mounting
B) Damage to the rear of the upper rib of the LH vertical stabilizer in the form of crack
shown in figure B.1.
Location of
Stop drill of the damage
crack
3 (Additional rivet)
Example 5. Fig B.1. Location of the rib damage
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Repair damage as shown below:
1. At the ends of crack drill 2.0 mm (0,078 in) hole.
2. Degrease the repaired surface and apply epoxy primer of any type for example:
7429-659-130, 830R or AERODUR CF PRIMER 3704.
3. Touch up paint as required
C) Damage to the edge of the rear bottom of the vertical stabilizer (below horizontal
stabilizer) (fig. C.1).
Stop drill of the

crack Location of
damage
Example 5. Fig. C.1. Place of damage
Damage repair as below:
1. At the ends of crack drill 2.0 mm hole (0,078 in).
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D) Crack the stringer in the area 10 rib LH vertical stabilizer.
Stop drill of Location

the crack of damage
Example 5. Fig. D.1. Place of damage stringer in the area 10 rib LH vertical stabilizer.
Repair the damage location as below:
1. Prepare the new stringer 28.00.3450.000.019 and cut length about 100 mm.
2. Remove from the damage stringer five rivets in the area of attachment.
NOTE
Not damage the skin of the vertical stabilizer during drilling of the stop holes
3. At the ends of crack drill 2.0 mm hole (0,078 in.).
4. Install new part of the stringer prepared in Step 1 with the 2.6x5-PA24-BN-70/1121-
06.
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E) Damage to reinforce division fairing of the LH Vertical stabilizer (Fig.E.1).
Location of
damage
Example 5. Fig.E.1. Place of damage to reinforce division fairing of the LH Vertical
stabilizer.
Repair the damage location as below:
1. Prepare a new reinforcement 28.00.3400.016.011.
2. Remove the tree mounting rivets reinforce.
3. In place of the current reinforce install rivets 2.6x7-PA24-BN-70/1121-05 new

reinforce.
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REPAIR MANUAL
EXAMPLE 6: Repair of the damaged rudder skin
Crack
Example 6. Fig. 1. Location of the rudder damage
1. Straighten the skin in the place of damage.
2. At the crack ends drill a 2.0 mm (0.078 in) dia. hole.
3. Prepare a strap out of 2024-T3 or 2024-T4 anodized sheet metal of 0.5 mm (0.0196
in) thickness and bend it in accordance with Fig. 2. Detailed dimensions of the strap to
be determined based on Figure 2 and actual damage on the rudder. When
determining the dimensions, pay attention to obtain the rivet distance from the strap
edge of at least 7 mm.
Example 6. Fig. 2. Size and approximate dimensions of the strap
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REPAIR MANUAL
4. Remove the existing rivets marked as “X” in Figure 3.
5. Insert one flange of the strap between the rudder skin and rib no. 4, and rest the other
flange on the rib. Locate and drill the rivet holes. To join the strap with the skin and the
rib use blind rivets (except for the rivet marked in black in Fig. 3). Maximum riveted
stack-up thickness 1.4 mm.
NOTE
Equivalent NAS rivets may be used in place of given rivet types .
6. Degrease the repaired area of the rudder skin.
8. Do not balance the rudder.
Example 6. Fig 3. Repair of the rudder skin crack
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REPAIR MANUAL
EXAMPLE 7: Repair engine cowling
B
A
Example 7. Fig. 1. Upper removable engine cowling – location of damage
REPLACEMENT OF HINGE OR COMPONENTS THEREOF (A):
1. In order to replace the damaged hinge or components thereof, proceed as follows:

• Remove the hinge pin (4);
• Take the spring (5) out – check it for technical condition; if any defects are found,
replace the spring with a new one;
• Drill out the rivets on the damaged hinge (hinge tab);
• Clean the surfaces that the hinge was removed from (hinge tab);
• Position the hinge tab or the hinge assembly in the installation location.
NOTE
It is advisable to install a washer (8) between the hinge tab (2) and the
deflectable cover in order to reduce the stress. The washer dimensions
are given in the Table.
• Transfer the rivet holes from the skin thru the hinge tab (tabs) (and washer);
• Rivet the hinge tab or the hinge assembly (ref. Note);
• If just one tab of the hinge is being replaced, position the spring (5) between the
hinge tabs and then join the hinge tabs and the spring with a new hinge pin (4).
2. Having degreased the processed surfaces, touch up the paint coatings.
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REPAIR MANUAL
Stiffener
Cowling
stringer Stiffener
Cover
stringer Cover
stringer
8
6 6
8
5
7
3
Deflectable 4
cover
Cowling
stringer
Example 7. Fig. 2. Replacement of hinge no. 28.14.6916.020.000 or components thereof
List of parts required for replacement of the hinge or components thereof:
ITEM Q-
PART NUMBER PART NAME NOTES
NO. TY
28.14.6916.020.000 Hinge 1
2 28.14.6916.020.003 .Hinge tab 1
3 28.14.6916.020.004 .Hinge tab 1
4 1-3-126-OST1.11187-77 .Hinge pin 1
5 1983A .Spring 1
6 3X8-PA25-BN-70/1121-06 Rivet 6
7 3X7-PA25-BN-70/1121-06 Rivet 4
2024-T3 or T4
8 Washer 1
≠ 1x105x13 [mm]
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REPAIR MANUAL
REPLACEMENT OF FRAME, REPAIR OF SKIN (B):

1. In order to replace the damaged frame (1), proceed as follows:
• Remove two rivets (2) joining the stiffener with the frame;
• Remove rivets (3 and 7) joining the frame with the attach brackets and the skin;
• Remove the damaged frame;
• Check condition of the other rivets (4), if condition is questionable – replace with new;
• Clean the surfaces that the above-mentioned parts were removed from;
• In place of the removed frame install a new one;
• Transfer the rivet holes from the skin, the attach angles and the stiffener thru the new
frame;
• Using appropriate rivets, rivet the frame to the skin, the attach brackets and the stiffener;
• Degrease the processed surfaces, touch up the paint coatings.
Skin
1
Attach
bracket
2
Stiffener
2
Attach
1
bracket 3
7 7
3
4
3
1 4
Example 7. Fig. 3. Replacement of the frame
2. Protect the skin cracks as follows:

• Stop drill the end of propagating crack;
NOTE
Pay particular attention so as not to damage the strap when stop drilling
the crack end.
• Clean and degrease the processed surfaces; touch up the paint coating.
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REPAIR MANUAL
Stop drill
location
Strap
Skin
Crack
Example 7. Fig. 4. Protection of the cover crack
3. The crack may be removed in two ways:

• Partial cutting out of the skin:
− In accordance with Example 7. Fig. 5, using any suitable method, remove the
cracking section of the skin;
NOTE
Pay particular attention so as not to damage the strap when removing the
cracking section of the skin.
− Remove the loose rivet from the strap, plug the resulting hole with a rivet;
− In a distance of 12 to 15 mm from the skin edge, drill and join the strap with the
skin using two rivets (5);
− Clean and degrease the processed surfaces; touch up the paint coating.
Skin
Strap
5
Contour of the skin

section cut-out
Example 7. Fig. 5. Partial cutting out of the skin
• Complete cutting out of the skin from underneath the strap:

− Remove rivets joining the strap with the skin, the frames and the stringer;
− In accordance with Example 7. Fig. 5, using any suitable method,
remove the skin;
NOTE
Pay particular attention so as not to damage the frames and the stringer
when removing the skin. In areas where the skin cutting line does not go
along the frames and the stringer pay attention to maintain the sufficient
section of the skin to be riveted with the strap.
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REPAIR MANUAL
− Rivet the strap using appropriate rivets.
NOTE
It is allowable to use the removed strap. To this end, plug the rivet
holes common to the skin and the strap.
• Clean and degrease the processed surfaces; touch up the paint coating.
7 Stringer 2
Frame
5 Skin
Strap
7 5
6 7 6
Example 7. Fig. 6. Complete cutting out of the skin from underneath

the strap.
List of parts required for replacement of the frame and repair of the skin:
ITEM Q-
PART NUMBER PART NAME NOTES
NO. TY
1 28.14.6916.000.047 Frame 1
2 3X6-PA24-BN-70/1121-06 Rivet 3
3 3X5-PA24-BN-70/1121-06 Rivet 6
4 3X6-1H18N9T-BN-70/1121- Rivet 1
05
5 3X5-PA25-BN-70/1121-06 Rivet 6
6 3X5-1H18N9T-BN-70/1121- Rivet 2
03
7 3X6-PA25-BN-70/1121-06 Rivet 16
28.14.6916.000.011 Strap 1 ≠ 1,0

[mm]
28.14.6916.000.071 Stiffener 1
28.14.6916.002.000 Attach Angle 2
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REPAIR MANUAL
EXAMPLE 8: Repair of collar crack of oil cooler tunnel in the lower engine cowling.
In case of repair of the crack the procedure below should be followed:
1) Remove the existing rivets (1) from the collar (3);
2) Remove rubber aerofoil (2);
3) Clean and degrease the points of crack from the painting coats;
4) Weld points of crack with SPA2 binding agent (ER5554 – substitute according to
AWS-A5.10 standard), protect against corrosion and supplement painting coats;
5) Install rubber aerofoil (2), rivet the collar with 2.6X7PA24BN-70/1121-06 rivets;
The above repair methodology should be used in case of occurring of similar cracks.
Example 8. Fig. 1. Places of cracks of the oil cooler tunnel in the lower engine cowling.
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3 A-A
NO. PART NUMBER PART NUMBER Q-ty NOTES

1 2.6X7-PA24-BN-70/1121-06 Rivet 34
2 4.5-25-1000-OST1.14253 Rubber aerofoil 1
Materials:
NO. PART NUMBER PART NUMBER Q-ty NOTES

1 SPA2 (ER5554) binding agent As required
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REPAIR MANUAL
EXAMPLE 9: Repair of the wing tip rib (No. 29).
When tip and rib are both damaged, they should be replaced, but in this case the wing tip
rib can be repair as follow.
REPAIR:
1. Remove damaged wing tip and attachment ribs of the wing tip.
2. Cut out part of the wing tip rib No.29 according to Fig. 1 (cutting line shown on this figure).
FWD
Upper web Filler Cutting line
Cutting line Lower web
Example 9. Fig. 1. Rib No. 29.
3. Manufacture a filler for cut out part of the rib from the same (or substitute) material and
thickness as the original material. Shape of the filler is shown on Fig. 1.
4. Remove in repair area rivets joining:
• The rib with the webs and rib with the bracket mounting rib to spar;
• The webs with skin.
5. Manufacture a doubler according to Example 9. Figure 2. Place the doubler against the
inboard face of the rib.
NOTE
Profile the doubler ending (the one that will overlap the angle joining the
rib with the spar) in such a way as to obtain precise adhesion of the
doubler, with its entire surface, to the other elements after the doubler
gets attached.
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REPAIR MANUAL
FWD
Doubler
Rib No. 29 Filler
Bracket
Example 9. Fig. 2. Doubler.
6. Place the filler in cut out part of the rib.

7. To match the filler and doubler and temporary connect with webs.
8. Transfer rivet holes from webs on the doubler.
9. Drill rivet holes in filler and doubler according to the figure 1.
10. Rivet using appropriate rivets:
• Filler with the doubler;
• Doubler with webs (without the places where the doubler is joined to the rib of the tip-
see Example 9. Figure 3).
Transfer the rivet holes from rib of the tip on the doubler with filler (Example 9. Figure 3).
Rib of the tip Mounting place of the second rib of the

No. 28.00.2200.000.016 tip No. 28.00.2200.000.014
FWD
Example 9. Fig. 3. Marking of the rivet holes for rib of the tip
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REPAIR MANUAL
11. Rivet the rib of the tip with the rib No. 29, the filler, bracket and doubler using
appropriate rivets.
12. Clean, degrease the repaired area and alodine and prime all parts.
13. Rivet the new wing tip.
List of parts required for replacement of the wing tip rib (No 29):
ITEM PART NAME Q- NOTES

NO. TY
1 Filler 1 2024-T3 or T4
≠ 0.5 [mm]
2 Doubler 1 2024-T3 or T4
≠ 0.6 [mm]
minimum
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REPAIR MANUAL
1.6. REPAIR OF EXHAUST PIPES
If any of the following are detected during the inspection proceed as indicated below:
1. Large burnouts - replace the pipes for new ones.
2. Repair burnt areas not larger than 10 cm2 (1.55 sq.in) by placing and welding stainless
steel cover plates 1 - 1.2 mm (0.04 - 0.05 in) thick per Fig. 78-3 having prior cut out the
damage part.
3. Cracks up to 20 mm (0.8 in) - drill dia 2 mm (0.078) holes at the ends of the crack and
then weld the crack.
4. Cracks up to 40 mm (1.6 in) - proceed as indicated under item 2 without prior cutting
out of the damage part.
NOTE
Dented areas do not require repair if there are no cracks or burnouts.
Fig. I-30. Schematic Drawing of Exhaust Pipe Repair
1 - exhaust pipe, 2 - cover plate
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REPAIR MANUAL
1.7. REPAIR OF PARTS OF GLASS LAMINATES
A. REMOVING SCRATCHES, CRACKS
1. Remove by means of glass abrasive paper the paint and primer along the score.
The cleaned area should be 30-50 mm (1.2-2 in) in width when repairing cracks, and 20-30
mm (0.8-1.2 in) when repairing scratches.
2. Prepare a patch of fabric INTERGLASS 92125 in diameters of the cleaned up

surface.
3. Degrease the cleaned-up surface with extraction naphtha, then with acetone and
dry for 15-20 min.
4. Spread a thin layer of K-153 glue (or substitute) on the cleaned-up surface and
put a patch of the dry fabric, smooth exactly, do not let any overlaps arise. Smear the whole
patch with glue, till it is exactly saturated.
Substitute product of the K-153: Epidian 57 + hardering agent Z-1

Epidian 57 – 100 parts by weight
Hardering agent Z-1 – 10 parts by weight
Substitute product of the K-153: HYSOL EE1067/HD3561 (resin/ hardering agent)

Resin HYSOL EE1067 - 100 parts by weight
hardering agent HD3561 - 15 parts by weight
5. Cover the patch with polyethylene foil, smooth by hand up to exact adhesion to
the surface (without swelling, and air bubbles).
6. Place the repaired part with the patch upward, put a polyethylene foil on the
patch, on the foil – a sack with sand and some weight, in order to receive a unitary pressure
on the patch not less than 0.1 kG/cm2 (1.42 lbs).
7. Keep the patch under load for 24 hours at at a temperature over 20°C (68°F)
until dry.
8. Using a knife or file, remove excess glue, clean the patch edges with the glass
abrasive paper to allow smooth transition to primary surface.
9. Renew the varnish surfaces.
20-30mm (0.8-1.2in) 20-30mm (0.8-1.2in)
Repair of delaminations
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REPAIR MANUAL
B. REMOVING OF DELAMINATION (CURLS)
1. With a knife, Cut out the damaged sector. The cut out outline should have a
shape as regular as possible. Edges of the cut out should have no cracks, delaminations and
be rigid.
2. With glass abrasive paper, remove the varnish coating around the cut-out. The
cleaned place around the cut-out should be 20-30 mm (0.8-1.2 in) in width.
3. Put a patch of the demanded number of glass fabric layers, it should fill up the cut-
out so as to remove the scratches. The last patch layer should cover the cut-out at a distance
of 20-30 mm (0.8-1.2 in).
4. Keep the patch under load for 24 hours at a temperature over 20°C (68°F) until
dry.
5. Using a knife or file, remove excess glue, clean the patch edges with the glass
abrasive paper to allow smooth transition to primary surface.
C. REPAIR OF DELAMINATION ON THE EYEHOLE COVER EDGES
1. Using an abrasive cloth, remove paint and primer from the eyehole edges (quoin)
in delamination area.
2. Degrease the cleaned-up surface with extraction naptha.
3. In place of delamination force in some glue of the DP100 type of 3M company.
4. When dry, i.e. after about 15 minutes in temperature of 20°C (68°F), clean the
repaired edge or quoin with the file (glass abrasive paper).
5. Touch-up the varnish covering as required.
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1.8. REPAIR OF THE OTHER ELEMENTS OF THE AIRPLANE
A. Damage of the skin (upholstery) of the single parachute seat
In the case of damage of the upholstery skin of the single parachute seat, made
of leatherette, replace the bowl of the parachute seat. If new bowl is not available, repair
the skin of the seat as follow:
1) Remove the single parachute seat from airplane by removing the cotter pin (6) and
bolt (2).
2) Remove screws (4) mounting bracket (3) to the bowl (5) of seat.
3) Remove rivets fixing upholstery skin form the bowl (5).
4) Remove upholstery skin from the bowl.
5) Cleaning bowl from the glue residue.
6) On the clean and degrease area apply new coating of the glue
7) Lay the new upholstery skin on the bowl. Color consistent with previous.
8) Rivet the upholstery skin to bowl with rivets of the same sizes as before
9) Screw the bracket (3) to the bowl (5) with the screws (4).
10) Install the single parachute seat in cabin.
Fig. I-38. Parachute seat
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Fig. I-38A. Parachute seat
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2. LANDING GEAR REPAIR
2.01. DAMAGE LIMITATIONS
2.01.1. Repairable damage limitations for main and nose landing gear elements (excluding
wheels).
• Damage to the lacquer coating – Touch up paint coatings.

• Scratches not over 0.15 mm (0.006 in) deep– Blend to remove scratch and touch up
paint.
• Dents on surface of landing gear cylinder or other elements not over 2 mm (0.078 in)
deep– Blend to remove dent and touch up paint.
• Damage of safetying elements (cotter pin) – replace damaged cotter pin.
• Corrosion on gear landing elements not over 0.15 mm (0.006 in) deep– Remove
corrosion and blend out wear and touch up paint.
2.02.2. Repairable damage limitations for wheels.

.
• Damage to the lacquer coating – Touch up paint coatings.
• Damage or corrosion not deeper than :
• 0.3 mm (0.012 in) in the place of packing ring.

• 0.5 mm (0.020 in) in the place where the tire beads bearing.
• 1 mm (0.040 in) on the remaining areas of the casting
Repair the damage as follow:
- Grind off damage or corrosion with emery cloth into wheel profile, without sharp
transitions, degrease the repair areas and apply priming paint Aerodur 37035A
and enamel Aerodur SGL Aluminium.
2.01.3. Not repairable damage limitations for wheels- replacement wheel
• Cracks
• Damage or corrosion deeper than :
• 0.3 mm (0.012 in) in the place of packing ring.
• 0.5 mm (0.020 in) in the place where the tire beads bearing.
• 1 mm (0.040 in) on the remaining areas of the casting
• Released bearing bushes

• Released outer bearing rings
• Released carier in the wheel drum (for main wheel only)
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a) Corrosion on matching b) Surface after grinding

surfaces left half and right
half of the wheel
c) Surface of the wheel hub after painting
Fig. I-40. Repair example (removing corrosion) on contact surfaces of main wheel
hub and wheel drum.
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REPAIR MANUAL
2.1. REPLACEMENT OF THE LANDING GEAR WHEEL BEARINGS
Replacement of the landing gear wheel bearings should be accomplished in case of the
following defects appearance:
- discoloration on rings faces, roller surfaces, rolling surfaces caused by the bearing
overheating
- corrosion;
-- crumbled and cracked rolls, cage and rings.
NOTE
1. If there is not apparent damage to the outer bearing ring
,replacement of the the complete inner rings only is acceptable,
however, rings must be of the same type and the same
modification as those removed.
2. Bearings with visible traces of an oxidation layer are allowed , i.e.

bearings with traces on the outer ring rolling surface or the bearing
tapered rolls surfaces, provided the face of the inner bearing ring
and the roller surface is not discolored due to bearing overheating.
A. REPLACEMENT OF THE MAIN WHEEL BEARINGS (FIG. I-47)
NOTE
The bearing outer rings can be cold-pressed from the hub. It is

acceptable to heat the hub up to max. 115°C (239°F) or to cool the
outer ring in a freezer in order to install the new bearings.
1. Press the 30214A bearing outer ring under the press using the K38-7100.11
block. Support the hub using the K38-7100.15 sleeve (Fig. I-48).
block. Support the hub using the K38-7100.16 tube (Fig. I-49).
3. Rinse the outer ring of the new bearing in petroleum spirit and dry it.
Mandrel (Fig. I-50). Coat the ring with operational grease.
Mandrel. Support the hub using the K38-7100.16 tube (Fig. I-51). Coat the rings with
operational grease.
6. Rinse the bearing inner rings with rolls of the new bearing in petroleum spirit.
7. Using an electric needle, write the number of the original bearings on the face of
the inner rings. These numbers must agree with the numbers on the hub faces (Fig. I-51).
NOTE
For writing, use the K38-7100.17 jig (Fig. I-52). The electric circuit
must not be closed through the cones, because it would cause
destruction of the bearings.
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8. Press a sleeve from the inner rings of the old 30311A bearing and press it into
the inner ring of the new bearing together with the bearing cover. Use the K38-7100.18
sleeve and the K38-7100.19 mandrel (Fig.. I-53).
9. Rinse the bearing inner rings in petroleum spirit and coat it with operational
grease.
Fig. I-47. Main Wheel Bearings

1-30311A Bearing; 2-Bearing Sleeve; 3-30214A Bearing
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Fig. I-48. Removal of the 30214A Bearing Outer Ring
Fig. I-49. Removal of the 30311A Bearing Outer Ring
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Fig. I-50. Installation of the 30311A Bearing Outer Ring
Fig. I-51. Installation of the 30214A Bearing Outer Ring
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Fig. I-52. Bearing Inner Rings Marking
Fig. I-53. Removal and installation of the 30311A Bearing Inner Ring Sleeve
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PAGE INTENTIONALLY LEFT BLANK
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B. REPLACEMENT OF THE NOSE WHEEL BEARINGS
Wheel disassembly (Fig. I-54) i.e. on separating the hubs and removing retaining
rings (3), packing rings (4) and sleeve (6) and (7), replace the 32010X bearings as follows:
1. Remove the bearing inner rings from the hubs by means of the K49-7110.0 jig
according to Fig. I-55.
NOTE
To simplify the bearing inner rings removal it is advisable to heat the
hubs in an electric furnace up to max. 120°C (248°F).
2. If necessary, i.e. on the ring (5) – Fig. I-54 defect detection; replace it. Remove
the damaged ring by means of the K49-7110-0 jig – Fig. I-55. However, use the claws with a
smaller cross-section for this purpose.
3. Remove the bearing inner rings from the sleeve (6) and (7) – Fig. I-54. Use the
jig for this purpose – see Fig. I-56a or I-56b.
4. Rinse the new bearing outer and inner rings in petroleum spirit and dry it.
5. Install the bearing outer rings in the hub by means of mandrel with of Φ85,5 mm
(3,366 in) diameter. Before installation it is advisable to cool the bearing rings in a freezer or to
heat the hub up to max. temp. 120°C (248°F).
6. Install the ring (5) – Fig. I-54 if it was removed. For installation use the mandrel
of Φ85,5 mm (3,366 in) diameter.
7. On the sleeves (6) and (7) cooled in a freezer install the bearing inner rings. For
installation use the sleeve of Φ50,5 mm (1.988 in) inner diameter. Put the sleeve of Φ51 mm
(2.007 in) inner diameter under the sleeve (6) and (7) where the bearing ring is installed.
8. Coat the bearing inner and outer rings with operational grease and assemble the
wheel.
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Fig. I-54. Nose Landing Gear Wheel
1 - 32010X bearing outer ring; 2 - 32010X bearing inner ring; 3 - retaining ring; 4 - packing
ring; 5-ring; 6,7-sleeve
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Fig. I-55. Removal of the bearing outer rings by means of the K49-7110-0
Fig. I-56a Fig. I-56b
Jigs for the 32010X Bearing Inner Rings Removal
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3. CONTROL SURFACES BALANCE
The control surfaces must be balanced after every repair or painting. The balancing should be
performed in a location free from violent air movements.
For ailerons balancing the 010.559.032699 fixture should be used, and for the elevator and
rudder balancing the work stands must be provided as shown on the sketches. The elevators,
rudders and ailerons must deflect smoothly.
A. AILERONS BALANCE
1. Assemble rig tool and position in a draft-free room (Fig. I-61).
2. Install the aileron in the rig in inverted position, i.e. bottom side up (reverse to that on
the airplane). Care must be exercised to properly set the rig's hangers so as to ensure aileron
span wise horizontal position of the aileron.
3. Position a weight of 290 G (0.639 lbs) at the aileron rear edge, along the aileron
counterweight (balancer) axis. If properly balanced, the aileron should assume a horizontal
position, with the trailing edge of the properly balanced aileron at the same level as a
corresponding indicator mark on the rig tool. If found otherwise, balance the aileron in accordance
to the procedure set forth in para. 4.
4. Balance aileron found out-of-balance, as follows:
- remove the rudder plug from the counterweight's back and remove the old leak
stopper;
- with the weight of 290 G (0.639 lbs) positioned at the rear edge of the aileron,
change the counterweight's mass until the aileron assumes horizontal position,
that is until the trailing edge aligns with the appropriate indicator mark on the rig
tool. Change the counterweight mass by drilling or filling with lead;
- remove the weight of 40 G (0.088 lbs) from the aileron rear edge; the aileron
should pitch forward nose down;
- coat the counterweight's inner surfaces with 7429-659-130 priming paint;
- check the drain hole at the counterweight's bottom for free clearance;
- install the rubber plug upon a film of leak stopper (PR 1442, PR 1431 or PR 1828)
on the counterweight. Also, form a ridge of leak stopper outside, around the plug's
perimeter.
5. Re-position hangers on the rig tool and check the other aileron for proper balance as
described above.
Procedure of balancing of aileron with the built ice protection installation is the
same as the procedure of balancing of aileron without the ice protection installation
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Fig. I-61. Aileron Balance Rig Tool
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B. ELEVATOR BALANCE
1. Carefully weight the elevator and record the result (Q SW ).
2. Suspend the elevator in the balancing fixture (Fig. I-62). The nose should turn
down.
3. At the elevator trailing edge within the center line of the rib No. 4, apply a control
load of the weight ensuring the elevator comes to a horizontal position.
4. Reduce the control load until the elevator starts deflecting from the horizontal
position, nose down, and record the weight of the load. This is the Q K1 (kg) weight.
5. Increase the control load until the elevator starts deflecting from the position of
balance, nose up, record the weight. This is the Q K2 (kg) weight.
7. Determine the moment per the following formula:
QK1 + QK2
MS = x l [kG cm] or [lbs in]
2
Where l = 43.4 cm (17.087 in)
8. The distance from the elevator center of weight to its axis of rotation (δ)
MS
δ = [cm] or [in]
QWS
Where Q SW indicates the elevator weight in a particular check.
The weight compensation is correct, when δ within 1.70 – 1.75 cm (0.669-0.689 in)
and the balancing operation is completed.
9. If δ is over 1.75 cm (0.689 in), remove the straps 28.15. 3230.150.000 or reduce
the weight of parts 28.00.3200.003.003; 28.00.3200.003.005 (by milling, drilling holes) and repeat
the balance verification operation. In this case, the elevator weight Q SW will decrease for the
value it was reduced.
10. If δ is below 1.70 cm (0.669 in), increase the balance load by applying additional
loads – straps 28.15.3230.150.000 and repeat the balance verification. In this case the elevator
weight Q SW will increase for the weights of these extra straps. The strap 28.15.3230.150.000 is
shown on sketch I-23.
11. The elevator rotation resistance is considered proper, when Q K2 – QK1 does not
exceed 0.04 kg. (0.088 lbs) If this condition is not met, grease the bearings to decrease friction.
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Fig. I-62. The fixture for the elevator balance
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Fig. I-63. Strap 28.15.3230.150.000

Material - steel; Q = ~56G (~0.123 lbs)
C. RUDDER BALANCE
1. Suspend the rudder in the balancing fixture (Fig. I-65).
2. At the rudder trailing edge within the center line of the rib No. 4, apply the
load Q = 0.120 – 0.130 KG (0.264 – 0.286 lbs), the rudder should come to a horizontal position
(the rudder chord).
3. If the rudder deflects automatically with the nose turned up, apply the balancing
plates 28.15.3330.061.000 (max. 9 off, application of the plate halves is acceptable) until the
rudder comes to a horizontal position. The plate is shown on Fig. I-64.
4. If the rudder deflects automatically with the nose turned, remove the balancing plates
or drill holes in the balancing load to regain the horizontal position.
5. Remove the load of 0.02 kg (0.044 lbs) from the trailing edge. The rudder shall
deflect for 25° with the nose turned down.
Fig. I-64. Balancing plate 28.15.3330.061.000

Material - steel; Q = ~65 G(~0.143 lbs)
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Fig. I-65. The fixture for the rudder balance
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4. CORROSION REMOVAL AND PREVENTION
4.1. GENERAL
1. The types of corrosion most commonly encountered on structural elements made of

aluminum alloy are surface corrosion and inter-ply corrosion.
Surface corrosion is formed in places where the protective coating is damaged. Signs
of corrosion are the presence of white or grey corrosion powder, or sometimes jelly-like
substance of the same colors.
The corrosion mentioned above manifests itself directly on the surfaces of the parts or
after having detected the corrosion centers under damaged lacquer coating or under the sealing
compound, or under bulged or separated layers on glue joints (particularly in the under-floor
space).
Inter-ply corrosion is formed mostly in the parts made of pressed semi-finished

products (working panels, wing spars, longerons, profiles) in the region of damaged protective
coating, during filing, in the region of joints and in slots. An outside sign of inter-ply corrosion is
the presence of irregularities on the parts surfaces in the form of bulges, cracks and ply
separation of the lacquer coating or the metal itself under the coating.
2. Parts made of magnesium alloys are least resistant to corrosion. Magnesium alloy
corrosion is manifested by coming out of the lacquer coating and formation of damp salt tarnish of
whitish color. Steel corrosion is manifested by formation of brown-red tarnish (rust) on the parts
surfaces.
3. To prevent corrosion of airplane parts, the preservation principles given below should
be strictly observed and simultaneously the protective coating damage removed.
- do not walk on the fuselage and wing skin, if necessary, put on special soft shoes,
or lay soft canvas mats which should be cleaned from dust, dirt, or snow before
beginning the work,
NOTE
The mats should not be stripped from the airplane surfaces, they should
be rolled and carefully removed.
- do not put tools, apparatuses, equipment or rags saturated with oil, kerosene, or
solvents on the skin,
- take care not to allow objects which could cause damage to fall on the fuselage
and wing skin,
- do not let alkalies, acids, fuel or oil penetrate to the parts,
- clean dirt from airplane surfaces ,
- when washing the airplane, do not allow water to get inside. Remove the causes of
water penetration, wipe the parts with a piece of cloth, remove water from difficult-
to-access regions with a pump,
- do not remove mud, snow, or ice with scrapers or by other mechanical methods,
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- ventilate the cabin and interior fuselage space, in winter it is necessary to blow the
interior with dry warm air,
- check and clean drain holes,
- if possible do not put on covers, apart from windshield covers, especially in winter
and autumn.
WARNING

are dependent on factors including work practices and task duration. Use appropriate
When installing covers over the windshields allow 5-10 centimeters (2-4 in) air space
between the covers and the airframe surface using special rubber washers or other waterproof
non-metallic materials and make sure the covers are pulled tight and will not strike against the
skin in case of windy weather.
4. When examining parts for corrosion, a 4-6x magnifying glasses and a non-metalic
scraper should be used. When inspecting dark places use a portable lamp. If there is doubt when
examining the parts for corrosion (in the case of surface corrosion) use the eddy current
inspection method with a flaw detector. It is allowed to use the eddy current inspection method
when the thickness of the lacquer coating is not more than 100 µm.
5. When corrosion is detected, the corroded parts should be prepared for corrosion
removal. Local corrosion to be cleaned to metal - coming out and cracked sealing compound,
lacquer coating, cracked spots and peeling of adhesive (in under-floor fuselage space). If
corrosion is found in the form of gaps in glued fuselage panel connections, the connection should
be unriveted. If corrosion is found on connection fittings-remove the connecting elements (drill out
the rivets, replace the bolts and nuts).
6. When the depth of corrosion does not exceed the value specified in the maintenance
procedures of the applicable section, remove the corrosion and refurbish the lacquer coating.
7. Remove corrosion in accordance with the below specified procedures.
8. After removal of corrosion, visually evaluate the quality of the surface cleaning in the
region of the corrosion centers with a magnifying glass, and if necessary, use the eddy current
inspection method flaw detector. If the corrosion has not been wholly removed, re-clean the area
to a depth of not more than 0.05 mm (0.02 in). After having removed the corrosion completely,
measure its depth and the remaining metal thickness of the particular part using a mechanical
depth gauge or ultrasonic depth gauge.
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4.2. REMOVAL OF CORROSION
A. SURFACE CORROSION ON ALUMINUM ALLOY PARTS
1. Remove corrosion with hard hair brushes.
WARNING
IT IS FORBIDDEN TO REMOVE CORROSION USING WIRE BRUSHES.
2. Clean corroded area and adjacent region with abrasive paper (region at the
distance of 5 - 10 mm (0.2-0.4 in) from the center of corrosion).
3. Remove the cleaning residues with pieces of cloth wetted in petrol with an addition
of anti-electrostatic agent. Wipe with a clean cloth and dry for 20-30 minutes.
NOTE
The areas of the fuselage floor panels to be dried for 1.5 - 2 hours at the
temperature of 70-80°C (158-176°F).
4. Evaluate the quality of corrosion removal.
B. INTER-PLY CORROSION ON ALUMINUM ALLOY PARTS
1. Remove corrosion from the whole depth and width of its occurrence. Use caution.
Remove layer by layer paying attention not to damage the parts or remove layers of metal not
attacked by corrosion.
2. Clean the corrosion center area with a (coarse) file until all corrosion has been
visibly removed, then clean the area with abrasive paper over the region at the distance of 5-10
mm (0.2-0.4 in) from the corrosion center. The transition between the cleaned surface and the
non-corroded surface should be smooth.
3. Remove cleaning residues, in accordance with it. A(3), and evaluate the quality of
the corrosion removal.
C. CORROSION ON MAGNESIUM ALLOY PARTS
1. Remove the corrosion by cleaning with abrasive paper 5 or 6 or a scraper.
2. Clean the detected corrosion areas with abrasive paper 5 or 6 until a glossy
uniform surface is obtained. The transitions between the cleaned surface and the non-corroded
surface should be smooth.
3. Remove cleaning residues in accordance with item A(3), and check the quality of
the corrosion removal.
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D. CORROSION ON STEEL PARTS
1. Remove the corrosion with a hard brush.
NOTE
Remove the contaminations (powder tarnish) from cadmium plated steel

parts (including attachment elements) with a clean piece of cloth.
2. Clean the corrosion center area with abrasive paper 5-8 until a glossy metal
surface is obtained. The transitions between the cleaned surface and the non-corroded surface
should be smooth,
3. Remove cleaning residues in accordance with item A(3), and check quality of the
corrosion removal visually or with a magnifying glass.
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5. REFURBISHING OF LACQUER COATING
NOTES
1. All work involving painting should be carried out at the temperature
of +15°C (59°F) through +35°C (95°F) and relative humidity of 35 -
80%. Before applying the lacquer coating check to ensure there is
no corrosion on the affected surface. If corrosion is detected,
proceed per par. 4.
2. The maximum thickness of paint coating is 150 μm except for the
areas with difficult access, color transitions, rivet surfaces, struts,
area over the cockpit, stub wings (areas where additional
protection against erosion is applied), fuel tank panel surfaces and
areas with insignia, marks and decorative symbols painted on.
5.1. PREPARATION OF SURFACE TO BE PAINTED
1. Wash the surface to be painted with a water solution of a preparation for airframe
washing removing dust, contamination, grease and exhaust gases traces. Rinse in running
water up to preparation complete removal. Wipe and dry.
2. Ground the airplane.
3. Pre-degrease by wiping with white cotton cloth or Kimvipe wiper saturated with
recommended degreaser.
a) Means generally appropriate for all metal surfaces:

- SOLVENT CLEANING C28/15 or
- SOLVENT CLEANING 96100 (not containing aromatic carbohydrates);
b) remover for plastics surfaces:
- SOLVENT CLEANING C25/2;
c) solvent substituting remover:
- ENVIROKLEN FD.
NOTE
It is admissible to apply the extraction naphtha.
Wipe surfaces dry with a second clean cloth – prior to evaporation of the solvent.
Degrease difficult to access areas, edges of connecting skin, riveted joints, bolt heads, and
nuts with bristle brush. Degrease in one direction only. Do not dip the cloth or brush in a
vessel. Apply the solvent by pouring from a small vessel. Replace cloths and wipers often with
new. Repeat this action until surfaces are clean. Let surfaces stand for 30 minutes too allow
evaporation of solvents .
NOTE
Due to the hazard of static electricity, perform work with clean and
balanced movements. Operators must use cotton cloth only and
head-gear. Perform work away from sources of open flame sources
and in places permeable to air. Avoid superposition and weeping of
cleaner on glazing.
4. Mask the airplane zones and equipment not intended for coating repair: propellers
and caps, tires and landing gears, data placards, bonding tapes, ferrules and gauging and
indicating points, rubber parts and stainless pats, radio equipment, antennas – with packing
paper and paste an adhesive tape around then. Carefully paste on edges of transparent parts:
cabin, reflectors and lights glazing with aluminum adhesive tape. Carefully press the tape to
the base. Apply two layers of polyethylene sheeting cut to the glazing shape. Stick edges of
the sheeting connection with aluminum adhesive tape overlapping ~10 mm (0.39 in) on the
tape originally stuck on edges. On the polyethylene sheeting masking additionally stick
masking from the packing paper and paper adhesive tape.
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5. Activate the surface for painting using red Scotch-brite needled cloth grade A or
240 abrasive paper (made of aluminum oxides) or finer one – to level the sharp edges.
NOTE
Avoid grinding to the base. In rivets, sheets connection edges use red
Scotch-brite needled cloth grade A only.
Remove the dust with a soft cotton cloth, dry brush and blow with clean
compressed air. Clean the Tack-region.
6. Degrease for finishing according to point (3). Leave for 30 minutes for degreasers
evaporating and for the degreased surface coming back to the ambient temperature. In case
of water condensation – dry with dry wiper and wait until water evaporates.
Auxiliary materials:
- KIMVIPE wipers,
- clothes of soft white cloth,
- packing paper (paraffin and silicones free) not dusting,
- aluminum adhesive tape,
- paper adhesive tape,
- polyethylene sheeting,
- red Scotch-brite needled cloth grade A, 3M Co.
- Tack-rag (commercial).
5.2. REFURBISHING OF LACQUER COATING ON OUTSIDE METAL SKINS
1. Prepare the surface to be painted according to point 5.1.
2. If surface has been taken down to bare metal apply the METAFLEX FCR PRIMER
metal conditioner. Advisable dry layer ~6÷10 µm (0.0002358 ÷ 0.0003937 in). Dry for 1÷2
hours, then immediately apply the epoxy primer.
3. Apply the epoxy primer, if its surface has been exposed. Use the 7429-659-130,
830R or AERODUR CF PRIMER 3704 primer. Dry and harder for 16÷24 hours.
4. After 24 hours of hardening, tarnish the base slightly with red Scotch-brite grade A
or the 320 abrasive paper (of aluminium oxides). Remove dust. Clean the surface with the
Tack-rag.
5. Paint in the repaired area with the IMRON-700 polyurethane enamel of a suitable
color, applying two layers:
- the first one thin, not covering (so-called 1/2 of the layer) dry 10÷15 minutes,
- the second full and covering layer apply crosswise with a 90° transition in
relation to the first layer. Dry and harden for 18-24 hours.
Remove masking
Before painting the next enamel dazzle colour, it is allowable to dry for 8 hours,
with keeping the hardening 24 hour-time of the last enamel colour applied on the airplane.
It is advisable to "loose" correction painting on the sheet edges connections or

riveted joints, what should be taken into account when the correction zone determining and
masking.
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6. On the glassy enamel total hardening – it is required on flat surfaces to improve

aesthetics or remove dustiness – polish with the REGULAR GRADE G6 or G3 abrasive
compound always wet with water by means of a very soft white cotton cloth. On polishing,
wash the residues with running water and wipe it dry.
7. Preparation and applying of the lacquer products.
Generally – carefully mix the base pigment, mix with the hardener according to
requirements, mix leave it covered for 15 minutes in order to initiate the reaction, for applying
with brush, thinnering is not required, for spraying thin according to requirements, do not use
after the working life expiration.
a) METAFLEX FCR PRIMER (wash primer) metal conditioner
Volume mixing:
1 part by volume of METAFLEX FCR PRIMER
2 parts by volume of METAFLEX FCTR HARDENER
0÷25% of C-25/90S Thinner
Absolutely prepare it in a glass vessel.
Working life in the temperature of 20±2°C (64.4 ÷ 71.6°F) – 6 hours.
b) 7429-659-130 grade B epoxy primer chemo-proof according to

ZN/RAFIL-2894:1999
Weight mixture:
4 parts by weight of the ground yellow base,
1 part by weight of 8222-897-000 hardener,
0÷25% of 8154-000-000 thinner
Working life - 10 hours
c) 830R chromium-free epoxy primer
Volume mixing:
4 parts by weight of 830R,
1 part by weight of 835R hardener,
1÷1,5 parts by weight of AU-370 thinner.
Working life – 8 hours.
d) AERODUR CF PRIMER 37047 chromium-free primer
Volume mixing:
2 parts by volume of Aerodur CF Primer 37047,
1 part by volume of S66/22R Hardener,
2 parts by volume of C25/90S or 98064 Thinner.
e) IMRON-700 ployurethane enamel
Volume mixture:
4 parts by volume of IMRON-700 enamel base,
1 part by volume of AU-270 hardener,
1÷1,5 parts by volume of AU-370 thinner.
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f) Chemo-proof epoxy enamel
Weight mixing:
3 parts by weight of 7462-000-XXX enamel base,
1 part by weight of 8222-897-000 hardener,
0÷25% of 8154-000-000 thinner.
5.3. REFURBISHING OF LANDING GEAR LACQUER COATING
2. Apply 7429-659-130 yellow epoxy primer according to point 5.2(3) and (7b).
3. Apply 7462-000-860 (light grey) chemo-proof epoxy enamel, in two layers always:
- dry the first layer for 1÷4 hours. After exceeding 4 hours – harden for 18 hours
and reactivate red Scotch-brite grade A and remove dust;
- dry the second cross layer and harden for 24 hours.
NOTE
It is allowable to paint with IMRON-700 color RAL7035 (light grey)
polyurethane enamel instead of epoxy enamel (light grey) according
to point 5.2(5) and (7e).
5.4. REFURBISHING OF LACQUER COATING ON PARTS INSTALLED INSIDE

AIRFRAME AND ITS INTERIOR SURFACES
2. If bare metal has been exposed, apply metal conditioner according to point 5.2(2)
and (7e).
3. Apply 7429-659-130 epoxy primer according to point 5.2(3) and (7b) with addition
of 1,5÷2% of PAP-2 aluminum powder (in relation to the base).
4. Paint the fuselage rear part behind Frame No. 21 and the cockpit and passenger
cabin floor surface upper part with 7462-000-860 chemo-proof epoxy enamel according to
point 5.3(3).
5. In zones under the cockpit and passenger cabin floor line paint with 7562-000-430
green epoxy enamel according to point 5.3(3).
6. Apply to Frame No. 9 wall and entry hatch framing only on the post paint with
UNO HD acrylic enamel in an appropriate color applying two layer always:
- dry the first layer for 10÷15 minutes,

- dry the second cross layer and harden for 18÷24 hours.
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Volume mixing:
4 parts by volume of UNO-HD enamel base,
1 part by volume of H8000 hardener,
1 part by volume of SC850 thinner,
4 parts by volume of MT849 structurizer.
5.5. REFURBISHING OF LACQUER COATING ON BOLT HEADS AND PROTRUDING

BOLT PARTS WITH NUTS
1. Prepare the surface to be painted according to point 5.1. Remove corrosion

according to point 4.
2. Apply 7429-659-130 epoxy primer according point 5.2(3) and (7b) with addition of
1,5÷2% of PAP-2 aluminum powder (in relation to the base).
3. Apply the second layer of the primer.
4. On surface outside the airplane apply two layer of IMRON-700 polyurethane

enamel in an appropriate color according to point 5.2(5) and (7e).
5. On internal surfaces apply two layers of the epoxy enamel or the polyurethane
enamel light grey according to point 5.3(3).
5.6. REFURBISHING OF FUSELAGE NOSE RADIO-TRANSPARENT LACQUER

COATING (APPLIES TO INTERNAL AND EXTERNAL SURFACE)
1. Prepare the surfaces to be painted according to point 5.1.
NOTE
Absolutely avoid the laminate structure grinding to the cloth layer.
After final degreasing, let stand for 2 hours before painting.
2. Apply locally dilute 830R epoxy primer with a brush according to point 5.2(3) and
(7c).
3. Apply locally 830R epoxy primer with a brush filling decrements according to point
5.2(3) and (7c).
4. Rub down dry the surface with abrasive paper No. 240 up to the surface leveling
and smoothing. Remove dust and clean with the Tack-rag.
5. If the outer skin decrements filling has not appeared satisfactory – repeat the
activity according to points (3) and (4) or in case of the deep decrements filling necessity – lute
by hand with FERRO MULTI putty and repeat activities according to points (4) and (2).
Smooth slightly with the P-320 abrasive paper and remove dust.
NOTE
It is inadmissible to leave superfluous thickness of putty or primer
layer. On rubbing down the filling materials may be left only in
decrements pits. It is forbidden to use other putties and primers with
metallic filer.
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6. On noses of the airplanes S/N AJE001-01 up to 1-10; AJE01-13 up to 1-18 apply

IMRON-700 polyurethane enamel of a color conforming to that one on the airplane (except for
colors with metallic filler) – according to point 5.2(5) and (7e).
7. On noses of the airplanes S/N AJE001-19 up to AJE002-10 apply PYROFLEX 7D

713 conducting polyurethane enamel (color black mat).
Volume mixing:
10 parts by volume of PYROFLEX 7D 713 enamel base,

3 parts of DURCISSEUR 0651 hardener,
7 parts of DILUANT 0651 or C25/90 THINNER.
Working life in the temperature of 20±2°C (64.4 ÷ 71.6°F) – 8 hours.
Mix dense base pigment very carefully and then mix for a long time with the
hardener and on the thinner adding. Apply one coating, dry for 10÷15 minutes, apply the
second cross coating. Dry, harden for 24 hours.
5.7. REFURBISHING OF LACQUER COATING LAMINATE PARTS
NOTE
Absolutely avoid the laminate structure grinding to the cloth layer
damage. On final degreasing, season for 3 hours (leave for the
solvents evaporating from the laminate internal areas).
2. Apply locally dilute LE 104 primer by means of a brush strongly frictioning in order
to fill pinholes in laminate.
3. Apply locally the filling layer of LE 104 primer with brush or spray – repeatedly in
order to level the surface. Dry between layers. Dry and harden.
4. Rub down dry up to the surface leveling with abrasive paper No. 240 or the finer
one. Remove dust, clean with the Tack-rag.
5. If the filling has not appeared satisfactory – repeat the activity according to points
(3) and (4) or in order to fill the deep decrements – lute locally with FERRO-MULTI and rub
down according to point (4).
NOTE
It is not allowable to leave superfluous thickness of putty layer. On
rubbing down the putty may be left in pits made by the damage only.
6. If it was luted with FERRO-MULTI – apply locally LE 104 primer according to point
(2) and (4).
7. Paint the cabin internal upholstery laminates with UNO-HD enamel of true colour
according to point 5.4(6).
8. Paint the outside contour laminates (except) from the fuselage nose):
- internal surfaces according point 5.3(3) and 5.2(f);
- external surfaces first according to point 5.3(3) and 5.2(7) and again according
to point 5.2(5) and (7e).
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Epoxy primer LE 104 (Du Point)
Volume mixing Weight mixing

LE 104 Base 5 parts 100 g (0.22 lbs)
250S hardener 1 part 12 g (0.026 lbs)
LE 305 solvent* 0,05 parts 0 to 5 g (0 to 0.011 lbs)
* For the first layer frictioning with brush, mix LE 305:

- 1,5 and more parts by volume
- 17 g and more parts by weigh
It is allowable to apply 1220R primer instead of LE 104 primer:

Volume mixing:
- 1220R Base 4 parts
- 1010R Activator 1 part
- 1220R Solvent 20 parts
For frictioning with brush apply 3,5 parts of solvent
5.8. REMOVING OF TEMPORARY MARKS ADHESIVE FOIL
The obligatory rule is unsticking from the shorted foil sheet dimension. Directly before
unsticking, soften the foil adhesive in unsticking area for example with hair drier with tube
outlet installed and next proceed unsticking immediately.
1. Unstick the foil sheet quoin from the left side with the spatula and deflect in such a
way, that catching the unstuck quoin with fingers would be possible.
2. Turn inside out the foil unstuck quoin in unsticking direction.
VERY IMPORTANT: While unsticking keep the angle of about

180°, but not lower than 170°.
Press with left hand the adhesive contact with lacquer coating on the airplane.
Unstick the foil slowly, smoothly with right hand – do not jerk.
The best way to proceed the above works is to proceed it by two workers at the same time
3. Wash the adhesive residues with cloth wet in denatured alcohol and wipe it dry.
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6. REPLACEMENT OF SEALS
6.1. REPLACEMENT OF SEALS ON THE HORIZONTAL STABILIZER

AND ITS DEFLECTORS
If damage is found on the horizontal stabilizer seals or its deflectors, in the place
of joining with the vertical fins, then replace such a seal, following the below procedure.
NOTE
Owing to a high labor consumption of the vertical fin removal and
installation, operations necessary for replacement of the seals
on the horizontal stabilizer and its deflectors, it is recommended
to replace all seals on a given side of the horizontal stabilizer
and on the deflector of the same side.
1. Remove the fin in accordance with Para. 55-31 A of the Maintenance Manual.
2. Rivet out the skin-to-seal connection (1, 2, 3 – on the horizontal stabilizer;
15, 20 – on the deflector) along with the strap (5, 6, 7 on the horizontal stabilizer)
or the plate (17, 22 on the deflector).
3. Locate a new seal in accordance with Figure I-66 (for the horizontal stabilizer)
and I-67 (for the deflector).
4. Lay out the rivet holes from the skin thru the seal.
NOTE
It is allowed to reuse the removed straps or plates. However, if they
require replacement, then after location of new ones, lay out the rivet
holes from the skin thru the new straps or plates as well.
5. Clean and degrease the areas being worked.

6. Coat the flat surfaces of seals with AK-20 adhesive on both sides.
7. Join the seal along with the strap or the plate with the skin by means of rivets
in accordance with Figure I-66 and I-67.
NOTE
When riveting, follow the rules prescribed in Para. 2.1 of Section II
of this Manual.
8. Clean and degrease the areas being worked, touch up the paint coatings.
9. Install the fin in accordance with Para. 55-31 B of the Maintenance Manual.
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11
10
A 5
B B
11
10
10
Fig. I-66. Horizontal stabilizer.
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Rib. No. 8 axis
B-B
6
2
Theoretical shape of the fin
10 5
Rib No. 8 axis
Fig. I-66. Horizontal stabilizer (cont.).

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6
6
1
1
3 7
12
12
Fig. I-66. Horizontal stabilizer (cont.).
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E
E
15
20
E-E
17
22
15
20
Rib No. 11 axis
13
Theoretical shape of the fin
Fig. I-67. Deflector.

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List of parts required for replacement of seals
IT. PART NUMBER NAME Q-TY NOTES

28.00.3150.000.000 Horizontal stabilizer
1 28.00.3150.000.017 Seal 2
2 28.00.3150.000.019 Seal 2
3 28.00.3150.000.015 Seal 1
5 28.00.3150.000.005 Strap 2
6 28.00.3150.000.007 Strap 2 For the one side
7 28.00.3150.000.009 Strap 1 Horizontal
9 3X8-PA25-BN-70/1121-06 Rivet 2 stabilizer
10 3X9-PA25-BN-70/1121-06 Rivet 64
11 4X9-PA25-BN-70/1121-06 Rivet 8
12 2.6X5-PA24-BN-70/1121-06 Rivet 7
13 3X7-PA24-BN-70/1121-05 Rivet 25
28.00.3103.010.001 RH Deflector
15 28.00.3103.010.007 Seal 1
17 28.00.3103.010.005 Plate 1
28.00.3103.010.002 LH Deflector
20 28.00.3103.010.013 Seal 1
22 28.00.3103.010.011 Plate 1
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7. REPAIR OF ELECTRICAL SYSTEM. GENERAL INFORMATION.
7.0. BASIC INFORMATION CONCERNING ELECTRICAL SYSTEM AND ITS REPAIRS.
Scope
This Section contains general data which may be useful when troubleshooting
wiring problems and minor repair to wiring terminations, and connections. This Section
does not define detailed procedures used for troubleshooting, or prescribe standard
procedures used for repairs of electrical systems such as: cutting of wires, soldering,
making harnesses, protecting, attaching, etc. This Section gives general information which
may be used when performing these procedures.
WARNINGS
1. Before proceeding with any work connected with verification, cleaning or

repair of the electrical system elements, ensure the appropriate circuit is
de-energized. If necessary remove external power, and disconnect
batteries.
2. Prior to re-energizing effected circuit, re-connecting batteries, or applying

external power, verify the following: integrity of repair, all FOD has been
removed, anyting disconnected has been re-connected, all covers,
shields, panels removed are properly re-installed, aircraft is safe to apply
power.
7.1. Wires
7.1.1. Wire Identification Code
All aircraft electrical wiring are identified by the identification code composed of:
circuit number designation, wire segment letter designation (R for radio and navigation
circuits) and wire number. The identification code is made by a series of letters and
numbers.
Figure 1A and 1B shows an example of a wire identification (identification code).
The wire identification code is applied directly on the wire insulation or the identification
sleeve. On shielded wires without outer insulation and on coaxial cables the identification
is applied on identification sleeves only.
Fig. 1A. Example of a wire identification code
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For a ground wire:
Fig. 1B. Example of a ground wire identification
NOTE
Wire segment is understood as a wire (or a few wires) of the same
potential.
7.1.2. Circuit number designation
Every electrical circuit in aircraft is provided with own specific number. The circuit
number designation identifies the circuit function. Table 1 shows circuit numbers
and their corresponding main functions.
Table 1. Circuit designating numbers

CIRCUIT CIRCUIT
NUMBER FUNCTIONS /SYSTEMS NUMBER FUNCTIONS /SYSTEMS
DESIGNATION DESIGNATION
Maximum Operating Speed
003 D.C. Sources 025 Warning System
004 A.C. Sources 026 Air-Conditioning System
005 Synchrophaser System 028 Pressure Refuelling System
006 Engine Ignition System 029 BYPASS Shutter Control
Fuel System Control-Long
007 Propeller Feathering System 030
Distance Flights
008 Engine Control Instruments 033 LC-2 Clock Power Supply
009 Fuel Consumption Control 040 Kannad 406 AF Transceiver
Traffic Alert and Collision
010 Fire-Fighting System 067 Avoidance Systems TCAS II
CAS 67A
Instrument and Control Panel.
011 073 520-10B Attitude Gyro
Back-Light
012 Hydraulic System 081 Flight data Recorder
Enhanced Ground Proximity
014 Anti-Icing System 090 Warning System (EGPWS
MKVI)
Ventilation and Heating
015 095 KHF 1050 Transceiver
System
Flaps, Trim Tabs and
016 101 Flap Diodes Box
Spoilers Control
017 Fuel Gauge System 104 Spoiler Diodes Box
018 Airframe Deicing System 122 KR22 Marker
019 SAS-4-9 System 124 KMA 24H-70 Intercom
KFC 325 Flight Control
020 Anti-Skid System 125
System
COMM/NAV/GPS
021 Internal Lighting System 134 GNS 430AW Systems
No.1
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COMM/NAV/GPS
021 Internal Lighting System 134 GNS 430AW Systems
No.1
COMM/NAV/GPS
022 External Lighting System 134 GNS 530AW Systems
No.1
023 Cargo Hatch Control 151 I pilot EFIS Indicators
Distance Measuring
163 251 II Pilot EFIS Indicators
Equipment KDM706A
LCR-92S12 No. 2
176 MST 67A Transponder 292 Attitude and Heading
Reference Systems
180 KDC 481 Air Data Computer 292 LCR 100 No. 2
181 RDR 2000 Weather Radar 300 A.C. Distributor Box
KDF 806 Automatic Direction
187 370 Light Box
Finder No.1
189 FA 2100 Magnetophone 730 Relay Box
LCR-92S12 No. 1
192 Attitude and Heading 806 A15 Trim Tab Box
Reference Systems
Power Supply System
192 LCR 100 No. 1 815
Relay Box
COMM/NAV/GPS Propeller Autofeathering
234 930
GNS 430AW Systems No. 2 Box
250 KRA405B Radio Altimeter
7.1.3 Wires Types used
7.1.3.1. Wire types used are shown in Table 2. (see table 6 for a list of proper wire
substitution).
Table 2. List of wires used in M28 airplane
It. Description It. Description

1 Antenna Cable D5102QX 31 Wire M27500-22TG1T14
2 CABLE D771553 32 Wire M27500-22TG2T14

3 CABLE RG 400 33 Wire M27500-22TG3T14
4 CABLE RG142 34 Wire M-E2219 STK1
5 CABLE RG178 35 Wire MGTF 0.12mm²
6 CABLE RG179 36 Wire M-K1037
7 CABLE RG214 37 Przewód M-K1219
11 CABLE RGT-400 41 Wire M-ZN1037
12 CABLE RK50-2-22 42 Wire M-ZN1237
13 COAXIAL CABLE ECS311201 43 Wire M-ZN1619
14 Wire BPDO-6mm² 44 Wire M-ZN1619STZ1
15 Wire BPGRL 0.35mm² 45 Wire M-ZN1819
16 Wire BPGRL-1mm² 46 Wire M-ZN2019
17 Wire FT40 47 Wire M-ZN2019STZ1
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18 Wire FTA-0.5 mm² 48 Wire M-ZN2219

19 Wire FTH 0.5mm² 49 Wire M-ZN2219STZ1
20 Wire H-GM21-E001 50 Wire M-ZN2419
21 Wire H-REE 4 51 Wire M-ZN2419STZ-1
22 Wire LYC-L 25mm² 52 Wire M-ZN6133
23 Wire LYC-L 95mm² 53 Wire M-ZN8133
24 Wire M27500-16TG2T14 54 Wire RT-16
25 Wire M27500-18TG1T14 55 Wire RT25
26 Wire M27500-18TG2T14 56 Wire RT50
27 Wire M27500-20TG1T14 57 Wire SG2M 25mm²
28 Wire M27500-20TG2T14 58 Wire SG2M-38mm²
Wire YPMY-EKW
29 Wire M27500-20TG3T14 59
3X0.35mm²
30 Wire M27500-20TG4T14
7.1.3.1. In identification of cables of RG…. type there may be additional letter

designations given by the manufacturer. The main section identifying the cable
type, and thus its electrical parameters and dimensions, is identification as for
example: RG 58, RG 178, RG 214, etc. Examples of additional designations: A,
/U, C/U, M17/93, etc.
7.1.4.Termination of wires into terminals and connectors
7.1.4.1. Termination of wires into terminals
7.1.4.1.1. All aircraft wiring has a termination at each end Examples are terminal lugs,
solder connections, crimp and solder pins and sockets for connectors, and end
caps. Table 7 shows a list of terminal lug substitutions.
Table 3. Typical, most commonly used wire terminals
Length of removable
Wire section
Terminal type 2 section of the wire
mm
insulation, mm
0,20 to 1,5 6,5
5837A 2,5 to 6,0 7,5
Above 10,0 8,5
4,0 to 10,0 14
16,0 18
5832A do 5834A 25,0 20
35,0 22
50,0 to 95,0 23
NOTES
1. Presently, the most commonly used are the substitutes of lug
terminals per the Table at the end of this Section. These are
crimped terminals. Terminals per the above Table are used until
the stock is exhausted.
2. Types of terminals used for particular circuit wires are given in
the connection tables for the made harnesses and in Bulletins
and Service Letters when fabrication of terminations is
necessary.
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7.1.4.1.2. To remove insulation from wires, wire strippers are used with blades designed
to strip various wire gages as marked on the blades. Using the proper size will
minumize causing nicking and damage to wire strands. It is allowable to remove
the insulation from wires by means of electrical singeing machine. It is allowable
to darken and flow the wire insulation along the length not longer than 3 mm in
the area of insulation removal. Removal of insulation by means of the singeing
machine should be performed only with the operating exhaust ventilation on
work stations.
Mechanical damage of the wire strands when removing the insulation by means
of the singeing machine is forbidden.
7.1.4.1.3. The length of insulated section of wires, depending on the electrical connector
type, should be 0.25-0.35 inches (7-12 mm) allowing for clearance of 0.1-0.2
inches (3-5 mm) between the soldering area and the wire insulation, when the
clearance of 0.1 inch (3 mm) should be used for wires of the section up to 0.14
inch (0.35 mm2) inclusive. This clearance is necessary to provide a flexible
transitory section between the terminal and the insulation surface. For the
crimped connections, the way of insulating of the wires is shown in the Figure
69A.
7.1.4.1.4. For stranded wires, after removal of insulation, their endings should be twisted
no more than ¼ turn in the direction of the existing twist.
7.1.4.1.5. Examples of terminating the wires into terminals are shown in Figures at the
end of this Section (Fig. 17,18, 19,20, 21). For termination of terminal lug given
in the substitutes column, there are universal crimpers used adapted to the
terminal types. Connector pins and socket are terminated with appropriate
crimpers with corresponding positioner.
7.1.4.1.6. After termination of the wire ending into terminal, the connection should be
insulated using heat shrink tubing appropriate for the wiring application (i.e.
environmental, insulating, anti-chafe etc.).
It is allowable to use other types of heat shrink tubes available at the operator’s
market in accordance with standards permitting application thereof in aviation, selecting
the one appropriate for a given temperature range.
7.1.4.2. Termination of wires into connectors
7.1.4.2.1. Termination of wires into electrical connectors shall be performed in accordance

with Figures 42-50. In the connectors with crimped terminals, pay particular
attention to lock the wire ending in the connector body latches.
7.1.4.2.2. Soldering of wires to connector pins/sockets, relay contacts the terminal strip
terminals, etc. shall be made in accordance with Fig. 3 and 4.
7.1.4.2.3. When connecting a wire of a strand diameter greater than the electrical
connector pin terminal hole diameter, use connecting sleeves in a number not
greater than 5 in one connector.
7.1.4.2.4. Soldering of two wires to the electrical connector pins shall be made in
accordance with Figure 22.
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7.1.4.2.5. In order to protect the soldered connections, use heat shrink tubes of RCSb
type of 1.0 +/- 0.25 inches (25+/-5 mm) length.
7.1.4.2.6. The electrical connector should be assembled in such a way as to exclude the
possibility of moisture or other fluids entering along the wires to the inside of
the connector a drip loop may be used in routing the harness, locate the drip
loop prior to the terminations at the connector. In the lower part, in the
protecting material,. make a drain hole. In areas of possible moisture ingress,
protect the harness connection with the connector by means of a cover, in
accordance with Figure 25.
7.1.4.2.7. Protection of the basic electrical connectors without sealing is given in the
Repair Manual, Section 2. Connectors of RS and RSG type shall be protected
by painting of a check mark. In order to protect the antenna connectors of „N”
and „TNC” type, use RITE LOK PS77 sealant.
7.1.4.2.8. In order to protect the connectors in the course of repair, use temporary plugs
supplied in a kit with the connectors or the others appropriate for that purpose.
7.1.4.2.9. Termination of electrical wires for the fire-fighting cylinder explosive cartridges
shall be made in accordance with Fig. 60.
7.1.4.3. General principles for repair of electrical wires
7.1.4.3.1. The repair of electrical wires can be performed by means of environmental

splices D-436-59, D-436-36, D-436-37, D-436-38. These four types of splices
are available in different sizes depending on the wire gage (AWG). They are
commonly color coded: red=26-20 AWG, blue=20-16 AWG, and Yellow=16-12
AWG. Drawing and dimensions of the sleeves are given below. It is allowable
to use another (equivalent) environmental splice locally available and permitted
to use in aviation.
Fig 3a. Linear joining of wires by means of D-436-36, D-436-37, D-436-38 joining sleeves
(cable boxes)
Fig 3b. Lap joining of wires by means of D-436-59 joining sleeves (cable boxes)
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7.1.4.3.2. Environmental splices shall be used in the event of transition of wires of greater
diameter into wires of smaller diameter, transition of two wires into one wire
when connecting to the contact of electrical connector, at the electrical system
branching connections.
7.1.4.3.3 Stagger multiple splices at differing lengths in a wire harness to prevent having
them all in one location creating a bulge.
7.1.4.3.4. Terminations of electrical wires into splices by means of crimping method shall
be performed in accordance with Figure 28.
7.1.4.3.5. For wires of section greater than 0.25 in (6.0 mm²) it is allowable to use the
wire bolted joint. Protection of the bolted joint shall be in conformity with Figure
37.
7.1.4.3.6. Repair of the wire insulation.
a/ If the wire protection layer (upper layer) is damaged, without exposure of the
wire stand, put a heat shrink tube on the damaged location. The area of
protection should extend 2.0 inches (50 mm) on each side of the damaged
area.
b/ If the wire insulation is damaged through the stand, or if the strand itself is
damaged, replace the damaged wire.
7.1.5. Wire harnesses
7.1.5.1. Harnesses are assembled from wires whose type, color, section and length are
given in the table of connections for every harness separately. The example of
a typical table of connections for a given harness is presented on the diagram:
Identification of harness is per the Album of Diagrams.
Main harnesses of airplane have the following designations:

Ф1, Ф2 ,ФЦ1 ,Ф3, Ф4, Ф10, ФЦ3, фЦ5, фЦ6, Җ81-K2, Җ81-K4, Җ81-K6, Җ81-K7, KЛ2,
KЛ3, X1, X2, X3, X4, X5, X3.1, X3.2, X4.1, X4.2, P1, P2, KL1 KLIM
The other harnesses (system ones) contain designations with the letter W and a number
of electrical circuit per Table 1 and successive number of the harness in this circuit, for
example: W192R1.
7.1.5.2. In the event of the electrical harness damage, its replacement should be
considered. Replacement of the main harness is a major repair and should not
be performed in service conditions. The system harnesses, depending on
service conditions, may be replaceable. If it is feasible to replace the harness, it
is recommended to order a new harness at the airplane manufacturer.
If a wire in the harness is damaged (it is cut or discontinued), it should be

disconnected from the connections, its endings should be insulated, and it
should be left in the harness, and a new wire of the same designation should
be lead in its place, and attached to the existing harness in the existing points
by means of a glass tape ASECz (b) of 1 mm diameter or 3K and 7K threads or
LTHT1B3NA string.
7.1.5.3. In order to increase reliability and protection against moisture, oil and other
fluids ingression, and against the effect of ambient conditions, harnesses are
protected by means of cloth or heat shrink tube.
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7.1.5.4. Damage of the harness protective material or heat shrink tubes shall be
repaired by replacement of the damaged protective material, if possible, or
adding a new section of protective material or heat shrink tube.
7.1.5.5. Examples of the harness attachment and fastening are given in the figures.
7.2. UNITS, ELECTRICAL CONNECTORS, CONNECTING BLOCKS, CONNECTORS

OF UNITS AND COMPONENTS.
7.2.1. Identification and repair of the electrical system elements
7.2.1.1. All elements of the electrical system are identified on their bodies and on the
airplane structure, next to the installation location in accordance with schematic
diagram and semi-assembly diagram given in the Album of Diagrams. Small
elements, such as circuit-breakers, switches, contactors, relays, resistors, etc.,
are identified by applying their designations directly on the structure next to the
installation location. The established letter designations for particular main
elements of the electrical equipments are given below:
A – Electromechanical control units

For example. 15–A1 where 15 - designates the circuit number (ref. Table 1 –
heating and ventilation system), and letter A
designates electrical control unit no. 1 in this
circuit. Successive finished products are
designated as A2, A3….
B – Sensors
For example: 15-B1 where: 15 - designates the circuit number (ref. Table 1 –
heating and ventilation system), and letter A
designates temperature sensor no. 1 in this
designated as B2, B3… .
C – Condensers,
For example 14-C1 where: 14 - designates the circuit number (ref. Table 1 –
ice protection system), and letter C designates
condenser no. 1 in this circuit. Successive
finished products are designated as C2, C3…
E- Electrical and radio & navigation units (finished products).

For example: 95-E1 where: 95 - designates the circuit number (ref. Table 1 –
KHF 1050 Transceiver system), and letter E
designates unit no. 1 Receiver/exciter in this
designated as E2, E3 in this circuit.
F – Circuit-Breakers,
For example 3-F1 where: 3 – designates the circuit number (ref. Table 1 – DC
current source system), and letter F designates
circuit breaker no. 1 in this system. Successive
circuit-breakers in this circuit are designated as F2,
F3…
G – Generators, current generators, starter-generators, transformers.

Designations are per the above rules.
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GB – Batteries. Designations are per the above rules.
H – Signaling lights. Designations are per the above rules.
K – Relays, contactors. Designations are per the above rules.
M – Electromechanisms. Designations are per the above rules.
P – Indicators. Designations are per the above rules.

PA – Ammeters
PV – Voltmeters
R – Resistors. Designations are per the above rules.

It is allowable to use substitutes listed in Table 5.
S – Circuit-breakers, switches
W – Antennas
Y – Solenoid valves
V – Diodes.
7.2.1.2. Diagram designations of connectors and connecting blocks.

Connectors are identified with the circuit number, letter X and the connector
successive number.
For example: 3-X1, 3-X2, 3-X3, etc.
Connectors at units are identified with the unit drawing number, letter X and the
connector successive number in the unit, for example 3-G1.X1.
Connecting blocks are identified by means of a special spacer located under
the connecting block, ref. Figure 7. If necessary, it is allowable to bond the
designation on the structure next to the connecting block.
7.2.1.3. In the event of the connector or the connecting block damage, replace the
connector or the connecting block. If the connectors are provided with
replaceable pins, replace the pins.
7.2.1.4. Connectors of 2RMT type are replaceable with connectors of 2RM type, and
connectors of 2RMDT type are replaceable with connectors of 2RMD type.
Connectors of 2RM and 2RMD type with the letter W at the end, are directly
replaceable with the above-mentioned connectors without the letter W at the
end.
7.2.1.5 Types and diagram designations of units and unit connectors
Types of units or (PN) in accordance with diagram designations, as well as types

of connectors are given on diagrams in the Album of Diagrams.
Generally, when the unit connector or the unit itself are damaged, the unit should
be replaced. If necessary, when there is no interference into the unit inside (for
example connector on harness of the unit), the unit connector can be replaced.
For connectors with replaceable pins, the pins should be replaced.
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7.2.2. Replacement of pins of connectors with replaceable pins

7.2.2.1. Removal of pins
Some connectors used on airplanes are provided with pins removed or inserted
from the rear (rear release). This is performed by means of a device (tool) made of plastic.
The disassembly part of the tool (for pulling out) is white, and the assembly part (for
inserting) is color coded depending on the electric wire size. The red-white color is used
for the 20 gage electric wire, blue-white for 16 gage electric wire and yellow-white for 12-
gage electric wire.
Procedure removal and insertion is as follows:

1. Position the ending of a tool for pulling out the electrical contacts (terminated with a
double plastic ending of appropriate size) at the connector insert back, on the electric
wire whose terminal is to be pulled out. Then press the wire through the insertion to
the plastic tool.
2. Slide the tool along the wire and insert into the insert cavity, until the tool engages the
locking mechanism and a positive resistance is felt.
3. Push in a wire of the contact which is to be pulled out, towards the tool serrations and
pull both the tool and the wire with the contact in such a way so as to pull out the wire
with the contact from the connector.
7.2.2.2. Installation of pins
NOTE
Care should be taken to prevent damage to the locking mechanism
which is delicate. Do not use force when inserting and pulling out of the
pins and contacts. Make sure that the appropriate tool is used. Do not
attempt to insert or pull out the wires from the forward side of connector.
1. Remove insulation from the electric wire along the length of approximately 1/4 inch
from the end.
2. Crimp the pin or the contact on the wire by using the apropriate crimper with the
proper positioner NOTE:.
NOTES
1. The DMC (Daniels Kit) is most commonly used and has charts
attached to the inside cover which will determine the type of
crimper and positioner required for each contact used in
connectors
2. After crimping of wire in the pin or in the contact, make sure the
wire can be seen through the inspection hole.
3. Holding the colored half of correct size pulling and inserting tool between the thumb
and the forefinger, slide the wire to be inserted along the tool slot. Leave approx. 1/2
inch of the wire visible. Snap the wire into the tool.
4. Pull the wire backwards through the tool until the tool tip seats against the contact
locking device.
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5. Holding the connector, slowly and gently push the contact straight into the connector
until the pin is seated and locked in place.
6. Release the wire and take the tool out.
7. Check for secure attachment by pulling the wire gently.
7.2.3. Preservation of electrical connectors, receptacles, plugs, wires and

harnesses.
7.2.3.1. Preparatory work.
1. Turn the power supply OFF.

2. Disconnect the batteries and the ground power supply from the airplane.
3. Disconnect the required (necessary) electrical connectors or coaxial
connectors, as required.
7.2.3.2. Preservation of electrical connectors, receptacles and plugs

7.2.3.2.1. Protection of electrical connectors.
Electrical connectors required special attention, when they are installed on

surfaces such as landing gear, landing gear bracket, wings, empennage and other
surfaces which may be exposed to salt water or salt water-laden air. The operations given
below will limit corrosion.
a. Protect the disconnected connectors with protective caps and plugs. Wrap
the disconnected connectors with plastic or barrier material in accordance
with the below Figure.
Bandage
of 8-10 coils of thread. Coat with
lacquer.
Connector
Balloon cloth
b. Special attention should be given to connectors with replaceable pins. These

connectors are provided with plastic inserts with unprotected contacts. This
type of connectors should be sealed against water ingression. The repeated
removal and replacement of the contacts and omission of the plastic inserts
may allow water entry.
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7.2.3.2.2. External corrosion removal and cleaning

1. Inspect the connector and the connector backshell for corrosion and corrosion
damage. If corrosion is heavy, the backshell may require replacing.
2. Remove corrosion with scotchbrite or similar material, if required.
3. Wipe the residues with cleaning cloth and clean with isopropal alcohol, or
electrical contact cleaner with a brush, then wipe dry with a clean, dry cloth.
4. Treat with proper corrosion preventative compound.
7.2.3.2.3. Internal corrosion removal and cleaning

1. Using a brush, clean inside surfaces of the connector pins with isopropal alcohol
or electrical contact cleaner.
2. Remove the isopropal alcohol or electrical contact cleaner and wipe the residues
with a clean, dry cloth or carefully with low pressure dry air.
7.2.3.2.4. Water removal and preservation
Coaxial connectors
Coaxial connectors require special steps to be taken to avoid water intrusion into
the connectors. In most cases, moisture, contaminants and corrosion in capacitive-type
connectors will cause erroneous quantity indications in the cockpit indicating systems. The
antenna coaxial connectors have similar moisture problems.
Water removal and preservation
1. Clean the coaxial connectors as follows:

a. Disconnect the connector sections.
b. Inspect both sections of the connector and, if required, remove corrosion by
means of abrasive material. Wipe the residues with cleaning cloth.
2. Clean both sections of the connector by spraying internal and external surfaces
of the electrical connector with isopropal alcohol or electrical contact cleaner.
Use a brush for cleaning the interior of the connector sections.
3. Wipe out the extra cleaner with cleaning cloth.
4. Assemble both sections of the connector and preserve the connector external
surfaces, applying a coat of the corrosion preventing compound.
7.2.4. Electrical wire harnesses and cables
1. When corrosion is found at a pin to wire connection on the electrical connectors,

the wire harness and the cables should be inspected for corrosion and cracking
of the wire insulation. The shielding of the coaxial cables are particularly
susceptible to corrosion. Clean the wire harnesses and the cables as follows:
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a. If corrosion is apparent at the back side of the connector it may be

necessary to remove 1-2 inches of the wire harness cable insulation in
order to inspect for corrosion.
b. Apply cleaner with a brush. Scrub the affected surface until the
contaminants are removed. Re-apply cleaner to flush the surface.
c. Remove (shake) the extra cleaner from the wire harness and wipe with a
clean cloth.
d. Allow to air dry.
2. If applicable, repair the electrical wire harness and the cable insulation.
7.3. POWER DISTRIBUTOR BOXES
Typical repairs of components in the power distributor boxes come down to repair
of terminals and replacement of bus bars. Typical repair procedures for distributor boxes
are shown in examples of Paragraph A.
A. TYPICAL REPAIR PROCEDURES (EXAMPLES).
A1. Typical procedure for replacement of terminals and bus bars in 28V DC
distributor box.
RELACEMENT OF TERMINAL:
In order to replace the damaged terminal, proceed as follows:
• Disconnect the power supply;
NOTE
Before starting the work, ensure all power is de-energized.
• Remove the 28V DC distributor box;

• Remove the adhesive compound from the rivet heads;
• Drill out the terminal attach rivets and remove the damaged terminal (1);
NOTE
Pay special attention not to leave drilling chips or other
elements that could lead to short-circuit in the bottom of the
box.
• Position a new terminal in the installation location;

• Rivet the terminal with rivets (2), protect the rivet heads with adhesive
compound;
• Install the 28V DC distributor box, connect all electric wires.
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NOTE
Make sure that all previously disconnected wires have been
properly connected.
2
Fig. 1. Terminal ANU7200.510.005 on 28V DC plate.
List of parts required for replacement of ANU7200.510.005 Terminal:
It. PART NUMBER PART DESCRIPTION Q-TY NOTES

1 ANU7200.510.005 Terminal 1
2 3X10-PA1-BN-70/1121-01 Rivet 2
REPLACEMENT OF BUS BAR

In order to replace a damaged bus bar, proceed as follows:
• Disconnect the power supply;
NOTE
Before starting the work, ensure all power is de-energized.
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REPAIR MANUAL
• Remove the 28V DC distributor box;

• Unscrew all nuts that attach circuit breakers or other bus bars to the bus bar to be
replaced;
NOTE
Pay special attention not to mix the removed washers and nuts,
since different installation kits are used in different locations.
• Remove the damaged bus bar;

• Degrease the terminal surface in location of the bus bar contact;
• Install and screw the new bus bar down;
NOTE
It is allowable to use the existing hardware after cleaning.
Hardware that is damaged, dirty or corroded beyond cleaning
must be replaced.
• Install 28V DC distributor box, connect all electrical wires.
NOTE
Make sure that all previously disconnected wires have been
properly connected.
List of parts required for replacement of 28.14.7223.526.000

and 28.14.7223.539.000WYD.1 Bus Bars:
It. PART NUMBER PART DESCRIPTION Q-TY NOTES

1 28.14.7223.526.000 Bus bar 1
2 28.14.7223.539.000WYD.1 Bus bar 1
3 M8-MO59-SN-BN-88/1117-21 Nut 2
4 ANU7200.513.017 Washer 2
5 3314A-8-O Nut 2
6 2154A-8-CD Washer 2
7 8-CD-OST1.11532-74 Washer 2
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B. TYPICAL TABLE OF CONNECTIONS - EXAMPLE
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C. TYPICAL CONNECTION AND TERMINALS
Fig. 3. Connection of wires to relay by means of a hole terminal
Heat shrink tube

to 2 mm
Wire
Insulator Terminal Heat shrink tube
Wires
to 2 mm
Insulator Terminal
Fig. 4. Protection of soldered connection with terminal
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Fig. 5. Typical identification of 2RM and 2RMD type connectors.
Fig. 6. Typical identification of power inputs
Fig. 7. Typical identification of connecting blocks
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Heat shrink tube

Wire Wire 0.2 mm2 to connection
Strand Wire 0.5 mm2 to body
Shield
for electrical connectors
Solder the wire strands
for terminals
Fig. 9. Typical connection of bonding wires to the BPDOE, BIFE, BFSE wire
shielding.
Heat shrink tube Shielding

Wire
Strand
Wire 0.2 mm2 to connection

for electrical connectors Wire 0.5 mm2 to body
for terminals
Protective sleeve
Solder the wire strands
Fig. 10. Typical connection of ground wires to the BPDOEZ and BIFEZ wire
shielding.
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Heat shrink tube
Insulation Shielding
Strand
Wire 0.5 mm2 to body
for electrical connectors Solder the wire strand

90
for terminals
Heat shrink tube

Ground wire strands
Shielding
Fig. 11. Typical termination of BIFE/BFSE wire Sheiding operated

operating in temperature conditions up to 250°C (482°F).
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Soldering sleeve Heat shrink tube
Shield
70 – 150
for electrical connector
90
Wire 0.2 to connection for terminals Strand
Wire 0,5 to ground

Wire
Solder
Do not check
Fig. 12. Typical termination of shielding by means of a soldering sleeve

A-before shrink, B- after shrink.
NOTE
For better clarity, sleeve and tube are shown as transparent parts.
Wire 0,5 mm2 to ground
Solder Shielding insulation
F4 Tape
Heat shrink tube
Wires
Shield
Fig. 13. Typical group termination of screened (shielded) wires
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Shielding
Wire Heat shrink tube

insulation
Fig. 14. Termination of shielding without lead to ground shall be
made as follows:
- For BPDOE wires – with RM TUT-1 tubes
- For BIFE wires – with RM TUT-2 tubes
- For BFSE wires – with TTK tubes
Shielding
Heat shrink tube
Fig. 15. Ground lead with a shield
Wire
Ground wire
Solder
Heat Shrink Shielding
Fig. 16. Ground lead with a wire
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Heat shrink tube
Terminal Wire
Terminal 5837A Heat shrink tube
Solder Additional heat shrink tube
Fig. 17. Termination of wires of sections up to 6.0 mm2 into terminals 5837A – in
accordance with 830 AT.
Terminal 6387A Heat shrink tube
Solder Wire
Fig. 18. Termination of wires of sections from 0.2 mm2 to 1.5 mm2 into terminals
6387A.
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Heat shrink tube
Wire
Terminal OST1 12320-75

Rubber tubes IRP-1338
Wire
Terminal OST1 12320-75
Fig. 19. Termination of wires into terminals OST 1 12320-75.
Terminal 5832A-5833A
Wire
Heat shrink tube
Terminal 5832A-5833A Wire
Fig. 20. Termination of BPDO wires of sections larger than 10 mm2 into terminals
5832A, 5833A.
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Wire BIF 0.35 mm to connection

0.5 mm2 to ground Solder the wire strands
Threads
BS6-13x1x4x6
Screen
Wire FKA-E, FKCH-E
Heat shrink tube
Crimp Soldering with

PŚr-40GOST 19798-74
F4 Tape
Presence of solder on
dimension A is not allowed.
Fig. 21. Termination of compensation wires into terminals
Tube TTF-1 RM TUT, TTK

Solder
Polyurethane foil of 0.15 mm2
thickness GOST10354-73
wind 3-5 coils
Wire
Electrical connector
Fig. 22. Soldering of two wires in one terminal
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Flatten when crimping Heat shrink tube
Wire
Fig. 23. Termination of spare wires and disconnected wires
Cap Wire
Fig. 24. Termination of spare wires with caps
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Fig. 25. Typical sealing of push-in connectors by means of protective covers
1 – Sealant (between the connector nut and flange);

2 – connector (insert);
3 – cover (heat shrink or equivalent);
4 – N3K thread bandage (tie per OST 103856-76);
5 – Sealant between wires and on the harness perimeter with a thick,
tights forcing in;
6 – connector;
7 – string tie (6-8 wraps);
8 – Sealant (between the connector nut and flange)
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Strand Insulation
TTØ-1, RMTUT, TTK
Wire
Fig. 27. Termination of M536-11 wire end into the electrical connector contact
2RMGD18B4Sz5E2
2RMGD27B19Sz5E2
2RMGD24B0Sz5E2
Fig. 27a. Numbering of pins in the 2RMGD type hermetic connectors
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1 – wires;
2 – heat shrink tube.:
For – 60ºC (333°F), +105ºC (378°F) – OST 1 12274-77
For – 60ºC (333°F), +135ºC (408°F) – OST 1 12273-77;
3 – OST 1 12273-77 joining sleeve;
4 – for – 60ºC (333°F), +105ºC (378°F) – polymer membrane
/MS 0.15x50 GOST 10354-73/, 2-6 layers,
– or heat shrink tube (RMTWT-2 in 2 layers –
The first one – 2 sections of approx. 10 mm length /compensatory,/
the second one per the figure;
5 – retainer;
Fig. 28. Termination of wires into joining sleeves
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Shielding Coaxial cable

RK
Washer (finished
product)
Rubber washer
(finished product) Threaded sleeve
Remove Solder (finished product)
inner
insulation
Remove outer
insulation
Cut the shield and solder in cut-outs along

Nipple
the whole perimeter of the nipple with solder
3-5 coils of tin-coated copper or silver-plated wire Ø 0.15

(f. ex. one strand of MS36-11 Ø 1.5 wire)
Fig. 31. Example of RK coaxial cable termination into SR connector.
NOTE
At SR-75-276, SR--75-278 and SR--75-279 connectors, split the
cable screens (shields) into halves and solder to conical sleeve.
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Protective cloth
Bandage ASECz (b), Adhesive

threads 3K or 7K
Fig. 33. String tying of harness made from BPDO, BIF, BFS wires for protected
harness. For unprotected harness, use string ties without protective cloth.
ASECz/b/ Ø 1-2 tube, soaked with

wax, heat shrink tubes or 3K, 7K
threads or LTHT1B3NA string.
Fig. 34. Tying of unprotected harness.
The bandage width depends on the harness diameter.
Harness diameter, mm (in.) Bandage width, mm (in.)

Up to 10 (0.4) 5-8 (0.2-0.3)
From 10 (0.4) to 20 (0.8) 8-12 (0.3-0.5)
From 20 (0.8) to 30 (1.2) 12-15 (0.5-0.6)
Above 30 (1.2) 15-20 (0.6-0.8)
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Body
Movable part
Wire
Protective sleeve
Clamp
Clamp Wire
Landing gear leg Fuselage
Clamp
Tubular axle
Wire
Protective sleeve
Mating surfaces (movable)
Protective sleeve
Fig. 35. Harness transition from movable into stationary part

a) movable part – body; b) landing gear leg – fuselage; c) mating
movable surfaces with tubular axle
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REPAIR MANUAL
Felt cloth
Wire
Protection
Sharp
d
Clearance
min. 10 mm
Wires arranged closer than 10 mm

Clamp with side attachment from the hole edge
Fig. 36. Protection of sharp edges of the structure elements
Heat shrink tube

Solder 02 BPDOU-0.2 wire
RK50-2-22 Cable
Terminal
28.00.7201.800.002
Fig. 36a Termination of RK50-2-22 cable and BPDOU wire into one pin
of 2RMD and 2RMDT connectors. Do not install heat shrink
tube for hermetic connectors.
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1-120
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Fig. 37. Typical fabrication of underslung contact connection of non-screened wires
1 – Teflon tube (inner) 6 – 3169-d-l-ł screw

2 – Teflon tube (outer) 7 – 3306A-d-l or 3314-d-l nut
3 – heat shrink tube 8 – 3408A-s-d-D-l flat washer
4 – bandage of threads no. 9 9 – 2154-d-kd lock-washer
(tying per OST 1 03856-76) 10 – d-k-d-OST 111532-74 spring washer
5 – 30MES-5 paste with tight fit
Revision 10
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REPAIR MANUAL
incorrect
correct
Fig. 38. Attachment of harnesses with clamps
Rivet Screw
Clamp Nut
Nut Clamp
Fig. 39. Typical attachment joints of electrical harnesses
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I
II
1) For RK-75 type cable
III 2) For RK-50 type cable
Fig. 40. Termination of RK type cable into connection
1 – heat shrink tube

2,3 – heat shrink tube TTF, RMTUT, TTK
4 – ground wire
5 – RK type cable
6 – connector
7 – 28.00.7201.800.000 terminal
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1 – heat shrink tube

2,3 – heat shrink tube TTF, RM
TUT, TTK
4 – MS36-11 ground wire
5 – RK type cable
6 – connector
The other details per Fig. 40.
Fig. 40a. Termination of RK type cable screens into connection
Terminal Braided
5837A- Heat shrink tube screen
Protective sleeve
Fig. 41. Termination of RK type cable in terminal strip.
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Insulation tubes
Solder sleeves F4 Tape, or fiberglass black shell
or RMTUT, TTK, tape
TTF tubes
Rubber sleeve or rubber
tape
Tie string for rubber

sleeve
Bond ground wire 0.5 mm2 behind

the closest clamp or under the
screw attaching the connector
Wire 0.2 mm2 through 583 7A terminal.
to connections
Fig. 42. Termination of mixed harness into non-screened connectors 2RM, 2RMD
and RPKM.
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Heat shrink tube
RETSAR cloth Use together with

rubber sleeve.
ŁETSAR tape Do not use for
ASECz /b/ Ø 1 rubber tape.
bandage
Rubber sleeve or rubber tape
Bandage ASECz /b/

Ø 1, threads 3K, 7K for rubber
sleeve
Harness protection per design

documentation
Identification tubes
Fig. 43. Termination of non-screened harnesses of BPDO, MS36-11, BPGRŁ,

LYC-1, LY105-L, BIF and BFS wires into non-screened connectors of
2RM, 2RMD, JK7 type.
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REPAIR MANUAL
Heat shrink tube
ŁETSAR tape or
ASECz /b/ Ø1
bandage
Rubber tape
Bandage (ASECz (b),

ŁETSAR)
Threads 3K or 7K
Protection of harness per

design documentation
Fig. 44. Termination of non-screened harnesses of BPDO, MS36-11, , BIF and

BFS wires into non-screened connectors of SzR 2RT type.
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REPAIR MANUAL
Heat shrink tube
ŁETSAR tape or
ASECz /b/ Ø1 Use together with
bandage rubber sleeve.
Do not use for
rubber tape.
RETSAR cloth
Terminal 5837A-
Rubber sleeve or rubber tape
Screen
Bandage
ASECz /b/ Ø1
Threads 3K or 7K
for rubber sleeve
Protection of harness per

design documentation
Fig. 45. Termination of screened harnesses of BPDOE , BIFE and BFSE wires
into non-screened connectors of 2RM and 2RMD type.
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Heat shrink tube

Length 10-15 mm
Sealant WGF-2
Fig. 47. Sealing of 2RM, 2RMD series connector cable part
Heat shrink tube

Rubber sleeve 1-OST111863-74
Washers
1-OST111866-74 Identification tubes
Bandage ASECz /b/ Ø1

Threads 3K or 7K
Fig. 48. Termination of wires into RS series pin connectors
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REPAIR MANUAL
Rubber tube (finished product), Glass threads

shorten to L=400mm ASECz(b) ø1
Solder
Protective material
Braid
(finished product)
Remove insulation and twist
Braided screen
Heat shrink tube
Fig. 49. Termination of DPS connector
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Designation of the
connector position
Fig. 54a example of applying designation of position on SR connectors
Rubber NO-68-1 or IPR

Connector Heat shrink tube
Wires
Apply designation of the connector

position on the opposite side.
Fig. 54b. Example of termination of wires into SzPŁM type connector
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I I
Braid
Bandage
ASECz /b/ Ø1
Fig. 57. Example of termination of a braid on harness
NOTE
Protect the harness under termination of the braid with two layers of ŁETSAR tape.
Bandage with ASECz(b)

glass tube
Harness
Protective tube
Connector Nipple
Braid
Fig. 58. Example of termination of screened harness into screened connector. For
unscreened harness, lead the braided screen to the length of 100mm from the
connector body and terminate in accordance with Fig. 57.
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Ring from connector assembly
RMTUT-2 Identification sleeve
Remove insulation on
l=20, bend and solder
with 02 solder
Solder the minus wire with 02

solder in the ring groove
Fig. 60. Example of termination of wires to connector from the explosive head assembly
NOTE:
In order to provide crimping of harness under the connector
clamp, wrap it with NO-68-1 rubber tape, 1.5 thick, 15 mm wide
L = terminal length + (0,7 to 1 ) d
Fig. 69a. Insulation of wires for crimped connections
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Fig. 69b. Tying of harnesses with LTHT1B3NA string
Fig. 69c. Termination of coaxial wires terminated with sleeves (for

example B-040-00-N)
NOTE
Do not use for antenna cables
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Screened wire or in braided screen

Unscreened wire
Heat shrink tube
Wire
Shield Tube RMTUT-2 l=7÷10 mm
Tape ŁETSAR 2-3 layers or
ISOLEPA
Fig. 103. Termination of 871/881 „rack and panel” connector for mixed harness
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A. Removal of insulation of the wire
B. Installation of A wire in the connector pin
Solder
C. Installation of B wires in the connector
Bandage
Fig. 107. Termination of connector with backshell
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A. Removal of insulation of the wire
B. Installation of single A wire C. Installation of two A wires in

in the pin the pin
Twist the wire
D. Installation of BC pins in the E. Installation of B, C pins in

connector, straight wires lead the connector, side wires
lead
Bandage
Bandage
NOTES:
1) crimp or solder the pins on B, C wires
2) make bandage in accordance with Fig. 34
Fig. 108. Termination of wires in the radio units connectors
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Bandage Solder Copper wire Ø0.5 mm
Heat shrink tube
C. Termination of braids (led as A and B) with BPDO-02 wire (wires)
Bandage Copper wire Ø0.5 mm

Solder
Heat shrink tube
D. Termination of braids (led as A and B) with DPDP-0,5 wire (wires) to ground
Fig.109. Lead of wires from braids and their connection with the wires connected to
ground through the connector and directly to the airplane structure.
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Reinforcing shield
Connector terminated in
accordance with Fig. 108D
Bandage
Fig. 110. Termination of radio connector with shield
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TABLE 6. SUBSTITUTES FOR MAIN TYPES OF ELECTRICAL WIRES
SIZE WIRE TYPE SUBSTITUTE SIZE

WIRE TYPE SUBSTITUTE
AWG mm AWG mm
BPDO-0.2 M-ZN2419 24 0.241
BPDOU-0.2 M-ZN2419 24 0.241
BPDO-0.35 M-ZN2219 22 0.382 BIF-0.35 M-K2219 22 0.382
BPDOU-0.35 M-ZN2219 22 0.382 BIF-0.5 M-K2019 20 0.597
BPDO-0.5 M-ZN2019 20 0.597 BIF-1.0 M-K1819 18 0.963
BPDOU-0.5 M-ZN2019 20 0.597 BIFN-1.0 M-K1819 18 0.963
BPDO-0.75 M-ZN2019 20 0.597 BIF-1.5 M-K1619 16 1.229
BPDO-1.0 M-ZN1819 18 0.963 BIF-2.5 M-K1219 12 3.022
BPDOU-1.0 M-ZN1819 18 0.963 BIFE-0.2 M-E2419STK1 24 0.24
BPDO-1.5 M-ZN1619 16 1.229 BIFE-0.35 M-E2219STK1 22 0.38
BPDOU-1.5 M-ZN1619 16 1.229 BIFE-0.5 M-E2019STK1 20 0.61
BPDOU-4.0 M-ZN1037 10 4.650 MS36-11-0.2 M-ZN2419 24 0.241
BPDO-6.0 M-ZN1037 10 4.650 MS36-11-0.35 M-ZN2219 22 0.382
BPDO-10.0 M-ZN8133 8 8.60 MS36-11-0.5 M-ZN2019 20 0.597
BPDO-16.0 RT16 (WHITE) MS36-11-0.75 M-ZN2019 20 0.597
BPDOE-0.2 M-ZN2419STZ1 24 0.24 MS36-11-4.0 M-ZN1037 10 4.650
BPDOUE-0.2 M-ZN2419STZ1 24 0.24 MS36-11-6.0 M-ZN1037 10 4.650
BPDOE-0.35 M-ZN2219STZ1 22 0.38 MGSZW-0.35 M-ZN2219 22 0.382
BPDOUE-0.35 M-ZN2219STZ1 22 0.38 H-GM21-E001 M81044/12-22-9/96
BPDOE-0.5 M-ZN2019STZ1 20 0.61 M27500-22TG1T14 M-ZN2219STZ1
BPDOUE-0.5 M-ZN2019STZ1 20 0.61 M27500-20TG1T14 M-ZN2019STZ1
BPDOUE-0.75 M-ZN2019STZ1 20 0.61 M27500-16TE1U14 M-ZN1619
BPDOUE-1.5 M-ZN1619STZ1 16 1.20 M27500-18TG2T14 M-ZN1819STZ2
BPGRŁ-0.35 FT40 M27500-22TG4T14 M-ZN2219STZ4
BPGRŁ-0.5 - M27500-20TG4T14 M-ZN2019STZ4
BPGRŁ-0.75 -
BPGRŁ-1.0 FR12
BIF-0.2 M-K2419 24 0.241
NOTE
1. Presently, the most commonly used are the wire types given in the Substitute
column. Wires from the WIRE TYPE column were used on previous airplanes,
and nowadays they are used only if they are available.
2. Diagram designations are printed on the wires. Identification is not printed on

wires above 6 mm², antenna wires, BPGRŁ , RK-50-2-22, M81044/12-22-9/96
wires. These wires are identified by means of identification tubes (sleeves).
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TABLE 7. LIST OF SUBSTITUTES FOR LUG TERMINALS
IT TERMINAL TYPE SUBSTITUTE NOTES

1 1-9-25-OST1,13702 34105
2 1-10-25-OST1,13702 34108
3 4-10-25-OST1,13702 34108
4 1-11-25-OST1,13702 130017
5 1-11-25-OST1,13702 130017
6 1-12-25-OST1,13702 31172
7 1-23-25-OST1,13702 34105
8 1-24-25-OST1,13702 34108
9 1-26-25-OST1,13702 31172
10 1-28-25-OST1,13702 B-106-1991
11 1-36-25-OST1,13702 34108
12 1-48-25-OST1,13702 34108
13 1-59-25-OST1,13702 34105
14 3-60-25-OST1,13702 34108
15 5832A-24-I KOA6-25 Crimp and solder
20 5837A-3-1 34108
21 5837A-14-1
22 5837A-15-1 34108
23 5837A-20-1
24 5837A-25-1
25 5837A-164-1
26 5837A-164-4 X
27 5837A-165-1 34108
28 5837A-165-3 34108 X
29 5837A-165-4 34108 X
30 5837A-169-1 34105
31 5837A-169-4 34105 X
32 5837A-170-1 34108
33 5837A-170-3 34108 X
34 5837A-170-4 34108 X
35 5837A-171-1 130017
36 5837A-172-1 31172
37 5837A-173-1 KOA8-1 Crimp and solder
38 5837A-175-1 34105
39 5837A-176-1 34108
40 5837A-176-3 34108 X
41 5837A-176-4 34108 X
42 5837A-178-1 31172
43 5837A-180-1 B-106-1991
44 5837A-181-1 34105
45 5837A-172-1 34108
46 5837A-182-4 34108 X
47 5837A-187-1 34105
48 5837A-188-1 34108
49 5837A-188-3 34108 X
50 5837A-188-4 34108 X
51 5837A-189-1 13017
52 5837A-193-1 34105
53 5837A-194-1 34108
54 5837A-194-4 34108 X
55 5837A-195-1 13017
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56 5837A-199-1 34122
57 5837A-199-4 34122 X
58 5837A-200-1 130106
59 5837A-201-1 34124
60 5837A-205-1 322454
61 5837A-206-1 130191
62 5837A-207-1 33458
63 5837A-211-1 322454
64 5837A-212-1 31805
65 5837A-213-1 33458
66 5837A-217-1 324061
67 5837A-218-1 31807
68 5837A-219-1 35247
69 6091S54-6 130106
70 6091S54-12 31805
71 6091S54-14 324061
72 6091S54-15 31807
73 F-2,5-Sn BN-85/3687- MS6,3/Sn Crimp and solder
02
74 H-2,5-Sn BN-85/3687- TS6,3/2Sn Crimp and solder
02
X -. One-time bending of equivalent terminals per the below figure is allowed.

Bend radius 2 mm.
NOTE
Types of terminals used for particular circuit wires are given in the
tables of connections for fabricated harnesses and in bulletins or
service letters where terminations are necessary.
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TABLE 8. LIST OF MATERIALS USED FOR TYPICAL MINOR REPAIRS OF

ELECTRICAL SYSTEM
IT. TYPE/DESIGNATION NOMENCALTURE STANDAD NO. NOTES

1 RCSb or RCESb Heat shrink tube ZN-94/ZUT-1/00
2 EXNŁ Braid -
3 PLc Braid PN-74/E-90161
4 TS Silicone tube -
5 OPCW PVC hose PN-89/C89209
6 NO-68-1 Rubber tape TU-005-1166
7 IRP1338 Rubber tape TU-005-1166
8 MS Polyethylene tape GOST 10354
9 AZT-s Technical cloth TU17-21-315
Connector cleaning and
10 KONTAKT 60
washing agent
11 ŁETSAR Adhesive tape TU38.103171
12 RAWMA12-455-757 Tape -
TU17RS FSR
13 ASECz (b) Dia 1 mm Cord
44-68-73
14 LTHT1B3NA String -
15 FRV1106 Sealant OST38.03238
16 RITE LOK PS77 Sealant OST38.03238
17 Torsol extra Torsol extra Threads PN-91/P-81111
18 TEX 150x3 Linen threads, glazed -
21 BWF-41 Adhesive BN-66/6357-02
22 WS-10T Adhesive GOST 22345
23 M63n 0,6 Wire PN-74/M-93830 0,5-T
24 M2G-N Wire PN-80/M-93830 Dia 0.5 mm
25 gca-CTs-Na Wire PN-67/M-80026 Dia 0.5 mm
26 LC40 Tin
27 PSr 2,5 Solder GOST 19798
28 Sn99,85 Wire- Solder PN-74/H-82204
29 Sn99,75 Solder PN-74/H-82204
30 LC1S1 Filler metal-solder PN-76/M-69400
31 Cynotop Flux -
32 OFMK ANC32-005 Flux
33 - Rectified spirit, pure PN-74/A79522
34 - Pine rosin PN-72/C-97501
35 7412000.000 Transparent lacquer BN-82/6114-40
ZN-93/MP-FL-
36 FTALUR Lacquer
3544
37 MS3367-4-9 Band clip
40 1-OST1.12273 Connecting cable box
NOTE
It is allowable to use equivalents (substitutes) of materials or
substitute materials approved for application in aviation, available
at the airplane operation location.
1-142 Revision 10
M28
REPAIR MANUAL
Table 9. LIST OF TOOLS USED FOR TYPICAL MINOR REPAIRS OF ELECTRICAL

SYSTEM
STANDARD
IT. TYPE/DESIGNATION NOMENCLATURE NOTES
NO.
1 28.00.9003.800.000 Suitcase with tools
1.1 28.00.9003.801.000 Teczka
Suitcase
1.2 Beta 55-5,5x7 Klucz płaski
Flat wrench
1.3 Beta 55-7x8 Klucz płaski
Flat wrench
Flat wrench
Flat wrench
Flat wrench
1.7 Beta 943BX-5,5 Klucz nasadowy

trzpieniowy
Socket wrench
1.8 Beta 943BX-10 Klucz nasadowy

trzpieniowy
Socket wrench

trzpieniowy
Socket wrench
Revision 10 1-143
M28
REPAIR MANUAL
STANDARD
NO.

trzpieniowy
Socket wrench
1.11 Beta 1714 Lusterko

Mirror
1.12 54106 ZN-PZL- Klucz do nakrętek w

854106 złączach
Spanner for connector

nuts
1.13 Beta 1274MQ- Wkrętak

0.5x3x100 elektrotechniczny
Electrotechnical
screwdriver

0.8x4x100 elektrotechniczny
Electrotechnical
screwdriver

1x5.5x125 elektrotechniczny
Electrotechnical
screwdriver

1.2x6.5x150 elektrotechniczny
Electrotechnical
screwdriver
1.17 Beta 1272MQ- Wkrętak krzyżowy

1x4,5x80
PH1x80 Cross screwdriver
1-144 Revision 10
M28
REPAIR MANUAL
STANDARD
NO.
1.18 Beta 920B-17 Nasadka
Socket end
1.19 ZN-PZL 854445-160 Wkrętak

antymagnetyczny
Non magnetic
screwdriver
1.19 Beta 1270BA-3 x 75 Wkrętak nieiskrzący
Non-scintillate
screwdriver
1.20 Beta 1229LP-1,4 Wkrętak

zegarmistrzowski
Jeweler`s screwdriver
1.24 Beta 1150MQ-160 Szczypce płaskie
Electrical flat pliers
1.25 28.00.9003.030.000 Puszka dla POS-40 i

kalafoni
Box for solder and

rosin
1.26 28.00.9003.020.003 Klucz nasadowy dla

elektryków
Socket wrench
1.27 28.00.9003.020.005 Klucz nasadowy dla

elektryków
Socket wrench
1.28 28.00.9003.040.000 Klucz do otwierania

zamków skrzynek
Special socket wrench
Revision 10 1-145
M28
REPAIR MANUAL
STANDARD
NO.
1.29 28.00.9003.010.000 Wkrętak do wkrętów w

złączach SzR
Screwdriver for
connector`s
1.30 Beta 1272MQ- Wkrętak krzyżowy

2x6x100
(PH2x100) Phillips screwdriver
1.31 28.00.9003.050.000 Wkrętak
Screwdriver
1.32 Wyrób gotowy Nóż

sześcioczynnościowy
Finished product
Jack-knife
1.33 Beta 1131CK Nożyczki
Scissor
1.37 28.12.9003.040.000 Klucz do otwierania

zamka skrzynek
Box lock wrench
Lutownica elektryczna
2
L-69-24/80W Electric Soldering Tool
28.00.8911.800.000 Lampa w pokrowcu
3 Lamp in cover
Market available
4 Cable cut shears
Adjusted to wire size
Market available
5 Skinning pliers
Market available
6 Terminal crimping pliers
1-146 Revision 10
M28
REPAIR MANUAL
IT. STANDARD
TYPE/DESIGNATION NOMENCLATURE NOTES
NO.
7 M22520/1-01 Crimper can be used a tools
8 M22520/2-01 Crimper 49935 or GMT1005
9 M22520/1-02 Positioner for wires of cross-
section 10-22
diameter, AWG and
10 M22520/2-02 Positioner
69363 for wires for
24-26 diameter
Revision 10 1-147
M28
REPAIR MANUAL
Page
1. MATERIALS USED FOR COVERS, FRAMES AND FLOOR REPAIR ...................................... 2-1
2. FASTENING ..................................................................................................................................... 2-
2.1. RIVETS .............................................................................................................................. 2-1
2.2. BOLTED JOINTS ................................................................................................................... 2-3
A. PROTECTION AND SEALING OF SEPARABLE CONNECTIONS .......................... 2-4
B. BOLTED JOINT SECURING ....................................................................................... 2-5
Contents
M28
REPAIR MANUAL
1. MATERIALS USED FOR COVERS, FRAMES AND FLOOR REPAIR
Generally the following materials should be used to repair the aircraft structures:
- cover plates for fuselage, frame and floor covering – K-2024T4-pl metal sheet of suitable
thickness;
- for sealing of the fuselage and fuel tanks - PR1422; PR1422A; PR1422B-2 leak stopper.
- in place of cloth patches used on airplane it is allowable to use the bonded 3M patches of
8681HS type of appropriate size
2. FASTENING
2.1. RIVETS
During the course of the repair the rivets are used to:
- replace the damaged rivets with new ones;

- install the repair cover plates;
- replace damaged parts which are attached to the structure with rivets.
To rivet using the existing (old) holes in the structural elements use rivets identical to the ones
which were removed, if the diameter of the hole under the rivet does not exceed 0.2 mm (0.008 in)
nominal diameter of ordinary rivets and 0.15 mm (0.006 in) for the rivets with compensators.
Otherwise use rivets one size larger.
The types, names, designation, material and marking of rivets are specified in table 2-1.
If the holes are battered having removed the old rivets, install rivets one size larger in the
quantity up to 10% in the seam, provided the larger diameter rivets are installed not more frequency
than one every three rivets.
Revision 10 2-1
M28
REPAIR MANUAL
Table 2-1
Type and Designation Material Shear Strength

Description kG/mm2 (lbs/sq.in)
BN-70/1121-01 PA 25 25 (35558)
With flat head BN-70/1121-01 PA 24 19 (27024)
BN-70/1121-01 PA 20 16 (22757)
BN-70/1121-01 PA 1 10 (14223)
With globe BN-70/1121-03 PA 25 25 (35558)

Head BN-70/1121-03 PA 24 19 (27024)
BN-70/1121-03 PA 20 16 (22757)
BN-70/1121-03 PA 1 10 (14223)
With 90° angle BN-70/1121-04 PA 25 25 (35558)

flat BN-70/1121-04 PA 24 19 (27024)
BN-70/1121-04 PA 20 16 (22757)
BN-70/1121-04 PA 1 10 (14223)
With 120° angle BN-70/1121-05 PA 25 25 (35558)

flat head BN-70/1121-05 PA 24 19 (27024)
BN-70/1121-05 PA 20 16 (22757)
BN-70/1121-05 10 34 (48358)
BN-70/1121-05 1H18N9T 44 (62582)
With oval BN-70/1121-06 PA 25 25 (35558)

countersunk BN-70/1121-06 PA 24 19 (27024)
head BN-70/1121-06 PA 20 16 (22757)
BN-70/1121-06 PA 1 34 (48358)
BN-70/1121-06 1H18N9T 44 (62582)
Tubular Rivet BN-70/1121-11 20, 20A 50 (71116)
2-2 Revision 2
M28
REPAIR MANUAL
2.2. BOLTED JOINTS
(1) It is forbidden to install bolts, nuts and washers with mechanical damage or signs of
corrosion.
(2) Before the installation clean the bolts, nuts and washers from contamination. If the bolts,
nuts and washers have been preserved remove the preserving grease.
(3) Before installing cover the bolt and hole surfaces with a protective lubricant, primer or
sealing compound coating according to the installation location of the bolt.
(4) The nuts not required the use of a torque wrench to be tightened manually with hand
until stop, using a standard open-ended spanner or socket wrench.
(5) When tightening movable connections (rockers-to-brackets) ensure free movement

(rotation) of the mating elements.
(6) The size of the threaded bolt part extending outside the nut should meet the following
conditions:
- the protrusion of the bolt end outside the nuts secured with cotter pins may be zero,
- the protection above the nut of the threaded bolt part with a lead cone should not be
less than the height of the cone,
- for a bolt with a shortened threaded part in connection with an ordinary thin nut the
protrusion of the threaded bolt part above the nut should not be less than one half of
the thread pitch,
- in other cases the protrusion of the threaded bolt part above the nut should not be
less than the pitch of the thread.
(7) When installing bolts requiring the use of a torque wrench for tightening, the below
procedure should be followed:
- select a nut for the given bolt and screw it on the threaded bolt part 2-3 turns (self-
locking nuts - only until the crimped part of the nut),
- lubricate the smooth part and thread of the bolt as well as the surface of the washer
adjacent to the nut with a thin layer of the AMS-3 grease (and for un-dismountable
bolts - with a thin layer of a primer or sealing compound), then wipe the bolt thread
with a piece of clean cloth to remove excessive lubricant.
NOTE
When installing bolts on primer or sealing compound screw on and tighten
the nuts with a wrench before the primer has dried or the sealing
compound has hardened.
- screw on the nut over the bolt with an open ended spanner and tighten it over the
protruding bolt part until stop,
- screw home the nut with a torque wrench to the torque moment value specified for the
given connection.
NOTE
It is forbidden to remove the clearance by increasing the torque moment
value specified for the given connection.
Revision 2 2-3
M28
REPAIR MANUAL
- apply a protective coating over the threaded bolt part and the nut,
- after tightening, checking for tight adhesion and applying protective coating paint the
mark with red paint HW-16 on the bolt and the nut.
A. PROTECTION AND SEALING OF SEPARABLE CONNECTIONS
A particular kind of protection and sealing is foreseen for each separable connection.
Protection of screw connections is carried out by means of protecting washers, cotters,

wire, metal deformation (punching) and self protecting nuts.
Screw connections sealing is done with pipe seals.
Electric connection protection is carried out by means of wire, sealing with pipe seals or
protecting plates.
NOTES
Change of one protection type for another in during assembly works is

forbidden.
Repeated utilization of sealing and protecting elements is not admitted.
2-4
M28
REPAIR MANUAL
B. BOLTED JOINT SECURING
a) Joint securing by means of protecting washers
When protecting screws and nuts with protecting washers (Fig. II-1) the following
conditions should be satisfied:
- protecting washer wings should be bent on the edge of the nut (screw) in position
of the washer turned in the unscrewing direction up to resistance of nose in the
socket of the part or a grip to the front of the part;
- bent washer grip should be strictly connected with the part. A clearance between
the washer and the part is admitted duly in the place of washer grip bending;
- putting washers on the collar and bending washer grips or their leaning against
the edge front should prevent washers from turning in the direction of unscrewing.
When protecting the washer grip bending, the protruding of the grip in relation to
the protecting collar front is not admitted;
- fitting washer wings in with nut (screw) walls should be carried out by tightening-
up the nut (screw) by an angle of no more than 30°, or exchanging the nut
(screw). Fitting by turning off the nut is not admitted.
- washer wings should be pressed against nut walls;
- bending washer wings may be done to one or to two walls of a nut (screw).
Bending reinforced wings to the wall carry out with this part of the bent wing
which ensures the biggest contact surface with the screw (nut) wall;
- bending washer wings should be carried out by means of special pliers.
In place of difficult access, washer wings bending may be carried out by means of
special holders or punches of copper or aluminium alloys.
The following is not allowed:
- cutting or displacement of material, cracks or tears at the washer wings bending;

- indents or flattening of washer wing when bending;
- bending wings more than once;
- wings protruding over the nut (screw) more than 2 mm (0.08 in);
- hammer traces at the washer wings bending;
- leaving washer wings unbent.
Revision 2 2-5
M28
REPAIR MANUAL
Fig. II-1. Protection with locating washers
2-6
M28
REPAIR MANUAL
b) Protection by means of cotters
When protecting nuts with cotters (Fig. II-2) the following requirements should be
fulfilled:
- fitting the hole for a cotter in a screw, tap screw and pin in the nut carry out by
means of tightening up the nut by an angle of maximum 30°, by the nut exchange
(screw, tap screw, pin) or by a proper selection of washer thickness.
Fitting by means of nut turning off is not admitted:
- cotter should be inserted into the hole freely or with a slight pressing;
- carry out bending cotter ends on nut walls with a punch of copper or aluminium
alloys, insert cotter ends in slots of the nut with a blunt screw-driver;
- cotter should hide in the nut slot.
It is admitted to let the cotter protrude over the nut slot maximum 0.4 of the nominal
nut diameter.
It is admitted:
- untight adhesion of cotter end to the nut surface in range of 0.1 ... 0.3 mm
(0.004..... 0.012 in);
- bent cotter ends touching the screw thread, tap screw, pin,
- cutting off cotters and burrs.
It is not admitted:
- taking off the cotter head;
- tearings and cracks on cotter ends;
- flattening or twisting of cotter ends;
- moving of the cotter after its mounting.
Revision 2 2-7
M28
REPAIR MANUAL
Fig. 20-2. Protection by means of cotters.
l = 0.5d - 0.75, where: d = diameter of screw, tap screw, pin
2-8
M28
REPAIR MANUAL
c) Protection with wire
In case of protecting with wire (Fig. II-3) the following conditions should be satisfied:
- diameter of the wire applied for protection should correspond to the diameter of
the protection hole in walls;
- the wire should be put so, that the tightening-up of the screw joint takes place by
any direction of load;
- wire should be winded without any jamming between coils.

Number of coils should be 3 to 5 at length of 10 mm (0.4 in) for a wire to 0.8 mm
(0.031 in) in diameter (inclusive), and 2 to 4 at a length of 10 mm (0.4 in) for a
wire more than 0.8 mm (0.031 in) in diameter:
- wire ends should be twisted (3-4 coils) and turned-up;
- in difficult of access places, by small distances between protected parts, it is

admitted not to wind the wire;
- wire should be stretched strongly, bendings, slackening, tearing and over winding
are not admitted.
2-9
M28
REPAIR MANUAL
Fig. II-3. Protection with wire
2-10
M28
REPAIR MANUAL
d) Protection by means of metal deformation
In case of protection by metal deformation (punching) (Fig. II-4) the following

conditions should be satisfied:
- do not control dimensions and location of punching places;
- when punching the thread, set the punch in the outlet of the screw, tap screw or
pin from the nut.
2-11
M28
REPAIR MANUAL
Fig. II-4. Protection by punching

S – pitch of thread;
M – designation of metric thread.
2-12 Revision 2
M28
REPAIR MANUAL
e) Sealing by means of pipe seals
When sealing (Fig. II-5) the following requirements should be fulfilled:
- carry out sealing with the aid of special seals;
- wire for fastening a seal should have no bend (3-4) coils, ends should be turned
up;
- seals should have no sharp edges and cracks;
- mark on the seal should be distinct.
Fig. II-5. Sealing with pipe seals
Revision 2 2-13
M28
REPAIR MANUAL
f) Protection and sealing of the connectors (couplers)
Protection and sealing methods of the connectors (electric connectors) are

mentioned below.
The following correspond to the drawing items:
1 - Protecting wire;
2 - Pipe seal;
3 - Connector,
4 - Bundle,
5 - Protecting plate,
6 - Tap screw,
7 - Washer'
8 - Nut.
Fig. II-6. Protection and sealing of the block part of unscrewed connectors 2RT, 2RMDT.
2-14 Revision 2
M28
REPAIR MANUAL
Fig. II-7. Protection and sealing of the cables parts of screened connectors 2 RT.
Fig. II-8. Protection and sealing of the cable parts of screened connectors 2RM, 2RMDT.
Revision 2 2-15
M28
REPAIR MANUAL
Fig. II-9. Protection and sealing of the cable part of unscreened connectors 2RM, 2RMDT.
Fig. II-10. Protection and sealing of screened connectors 2RT.
2-16 Revision 2
M28
REPAIR MANUAL
Fig. II-11. Protection and sealing of screened joints 2 RM, 2RMDT.
Fig. II-12. Protection and sealing of unscreened joints 2 RT.
Fig. II-13. Protection and sealing of not screened joints 2 RM, 2 RMDT.
Revision 2 2-17
M28
REPAIR MANUAL
SECTION III. REPAIR CONNECTIONS

CONTENTS
Page
1. FUSELAGE ................................................................................................................ 3-1
1.1. Nose landing gear attachment upper and side joint ............................................3-1
2. WING ....................................................................................................................................3-2
2.1. Centerwing-to-fuselage attachment bottom joint on the front spare ............... 3-3
2.2. Centerwing-to-fuselage attachment bottom joint on the rear spar..................... 3-4
2.3. Outboard-to-centerwing attachment upper and bottom joint on the
front spar.................................................................................................................... 3-5
2.4. Outboard-to-centerwing attachment upper and bottom joint on the
rear spar ..................................................................................................................... 3-6
2.5. Strut attachment upper joint .................................................................................... 3-7
2.6. Strut attachment bottom joint ................................................................................. 3-8
2.7. Ailerons attachment joints ....................................................................................... 3-8
2.7.1. Aileron attachment on the wing rib No.19 .................................................... 3-8
2.7.2. Aileron attachment on the wing rib No. 22 ................................................... 3-9
2.7.3. Aileron attachment on the wing rib No. 26 ................................................... 3-9
2.7.4. Aileron attachment on the wing rib No. 29 ................................................. 3-10
2.8. Inner spoiler attachment joints ............................................................................. 3-10
2.8.1. Spoiler attachment on rib No. 12 ................................................................. 3-10
2.8.2. Inner spoiler control attachment, rib No. 14 .............................................. 3-11
2.8.4. Inner spoiler control attachment joint on the wing ................................... 3-12
2.9. Outer spoiler attachment joints ............................................................................. 3-13
2.9.1. Outer spoiler control ..................................................................................... 3-13
2.9.3. Spoiler attachment on rib No. 27 and rib No. 28........................................ 3-14
2.10. Aileron trimmer control joint ................................................................................. 3-14
2.14. Slats-to-outboard wing attachment joints ........................................................... 3-17
2.14.1. Fitting on the slat, slat rocker, rib No. 11 .............................................. 3-17
2.14.2. Bracket on the nose, slat rocker, rib No. 11 .......................................... 3-18
2.14.11. Bracket on the slat, slat rocker, rib No. 28 ............................................ 3-27
3. EMPENNAGE .................................................................................................................... 3-29
3.1. Tail plane attachment joints on the fuselage .................................................. 3-30
3.2. Elevators attachment joints ................................................................................... 3-31
3.3. Rudders attachment joints .................................................................................... 3-34
4. MAIN LANDING GEAR .................................................................................................... 3-37
4.1. Connecting rod-to-main landing gear assy attachment bottom joint ............. 3-38
4.2. Main landing gear connecting rod-to bracket of the landing gear
attachment in the fuselage upper joint................................................................. 3-39
4.3. Main landing gear assy-to bracket of the landing gear attachment in the
fuselage front joint .................................................................................................. 3-40
5. FIT INTERCHANGERS ..................................................................................................... 3-41
Revision 2 Contents
M28
REPAIR MANUAL
1. FUSELAGE
1.1. Nose landing gear attachment upper and side joint
Detail A
Pos. Drawing, standard No. Dnom. Overhaul Diameters Xmin Notes

[mm] [mm]
1 2 3 4
1 28.00.0120.010.000 24H8 - - - 25H8 17,5
2 28.14.4203.120.000 20H9 20H9 20,2H9 20,6H9 20,8H9 5
3 1-20-24-10-2,5Cd 20H9 20,2H9 20,4H9 20,6H9 20,8H9
OST1 11124-73
4 28.00.4200.001.000 20h6 20,2h6 20,4h6 20,6h6 20,8h6
Detail B
Pos. Drawing, standard No. Dnom. Overhaul Diameters Xmin

[mm] [mm]
Notes
1 2 3 4
1 28.00.4211.001.000* 35H9 35,1H9 35,2H9
- - 5
28.14.4203.120.000 8H8 8,2H8 8,5H8
2 28.00.4210.001.000* 35h8 35,1h8 35,2h8 Treat with
- - chromium
28.14.4200.306.000 8H8 8,2H8 8,5H8
3 28.00.0130.002.000* For sleeve
35H7 35,1H7 35,2H7 - - 2,9
28.00.0130.008.000
4 3024A-8-62-4Cd* Thread M8
8,2f9 8,5f9 - -
3024A-8-64-4Cd
*) Effectivity to S/N AJE001-18
3-1
M28
REPAIR MANUAL
2. WING
1. Centerwing-to-fuselage attachment bottom joint on the front spar.

2. Centerwing-to-fuselage attachment bottom joint on the rear spar.
3. Outboard-to-centerwing attachment upper and bottom joint on the front spar.
4. Outboard-to-centerwing attachment upper and bottom joint on the rear spar.
5. Strut attachment upper joint.
6. Strut attachment bottom joint.
7. Ailerons attachment joints.
8. Inner spoiler attachment joints.
9. Outer spoiler attachment joints.
10. Aileron trimmer control joint.
14. Slats-to-outboard wing attachment joints.
3-2
M28
REPAIR MANUAL
2.1. Centerwing-to-fuselage attachment bottom joint on the front spare

[mm] [mm]
1 2 3 4
1 28.00.1000.013.000 D1 12,2H7 12,4H7 12,6H7 12,8H7 10,0 Roughness class
=12H7 of treated surface
1,25
1,25
3 1-D3-D2-12Cd D3 12,2H7 12,4H7 12,6H7 12,8H7
Ost1 11119-73 =12H7
D2 15,2u8 15,4u8 15,6u8 15,8u8
=15u8
4 28.00.2000.001.002 D1 12,2f7 12,4f7 12,6f7 12,8f7 Roughness class
=12f7 of treated surface
1,25
5 3402A-1-Dw-20 Dw 13 13
Repair washer (Dinn) - -
=12,5
6 12656029 Dw 13 13
GOST 6402-70 (Dinn) - -
Repair washer =12,5
3-3
M28
REPAIR MANUAL
2.2. Centerwing-to-fuselage attachment bottom joint on the rear spar

[mm] [mm]
1 2 3 4
1,25
1,25
3 1-D3-D2-12-Cd D3 12,2H7 12,4H7 12,6H7 12,8H7
OST1 11119-73 =12H7
Repair sleeve D2 15,2u8 15,4u8 15,6u8 15,8u8
=15u8
4 28.00.2000.001.002 D1 12,2f7 12,4f7 12,6f7 12,8f7 Roughness class
=12f7 of treated surface
1,25
5 3402A-1-Dw-20 Dw 13 13
Repair washer (Dinn) - -
=12,5
6 12656029 Dw 13 13
GOST 6402-70 (Dinn) - -
Repair washer =12,5
3-4
M28
REPAIR MANUAL
2.3. Outboard-to-centerwing attachment upper and bottom joint on the front spar
Detail A, B

[mm] [mm]
1 2 3 4
Detail A
1 28.00.1001.015.000 16H7 16,5H7 17H7 17,5H7 18H7 8,5
2 28.00.2101.003.000 16H7 16,5H7 17H7 17,5H7 18H7 8,5
3 28.00.2000.001.001 16f7 16,5f7 17f7 17,5f7 18f7
4 3402A-2-D-30 16,5 - 17 17,5 18
Detail B
1 28.00.1001.016.000 12H7 12,5H7 13H7 13,5H7 14H7 10,5
2 28.00.2101.004.000 12H7 12,5H7 13H7 13,5H7 14H7 10,5
3 28.00.2000.001.003 12f7 12,5f7 13f7 13,5f7 14f7
4 3402A-2-D-25 12,5 - 13 13,5 14
3-5
M28
REPAIR MANUAL
2.4. Outboard-to-centerwing attachment upper and bottom joint on the rear spar
Detail A, B

[mm] [mm]
1 2 3 4
Detail A
1 28.00.1002.003.000 16H7 16,5H7 17H7 17,5H7 18H7 8,5
2 28.00.2102.003.000 16H7 16,5H7 17H7 17,5H7 18H7 8,5
3 28.00.2000.001.001 16f7 16,5f7 17f7 17,5f7 18f7
4 3402A-2-D-30 16,5 - 17 17,5 18
Detail B
1 28.00.1002.004.000 12H7 12,5H7 13H7 13,5H7 14H7 10,5
2 28.00.2102.004.000 12H7 12,5H7 13H7 13,5H7 14H7 10,5
3 28.00.2000.001.003 12f7 12,5f7 13f7 13,5f7 14f7
4 3402A-2-D-25 12,5 - 13 13,5 14
3-6
M28
REPAIR MANUAL
2.5. Strut attachment upper joint

[mm] [mm]
1 2 3 4
1 28.00.2050.110.000 24H8 24,2H8 24,4H8 24,6H8 24,8H8 20,0
2 28.00.2103.011.000 24H8 24H8 24,2H8 24,4H8 24,8H8 20,0
3 1-20-D-8-2-Cd 24u8 24,2u8 24,6u8 24,6u8 24,8u8 Roughness class
OST1 11124-73 1.25
Repair sleeve
4 1-20-D-14-Cd 24u8 24,2u8 24,6u8 24,6u8 24,8u8 Roughness class
OST1 11119-73 1.25
Repair sleeve
3-7
M28
REPAIR MANUAL
2.6. Strut attachment bottom joint

[mm] [mm]
1 2 3 4
1 28.00.2050.120.000 D2 41,2H8 41,4H8 41,6H8 41,8H8 20,0
2 28.00.0230.073.000 D1 22H8 22,2H8 22,4H8 22,6H8 23,7
28.00.0230.800.000
3 1-20-D-10-Cd - 22u8 22,2u8 22,4u8 22,6u8
OST1 11119-73
Repair sleeve
4 28.00.2050.122.000 41u8 41,2u8 41,4u8 41,6u8 41,8u8
Repair sleeve
2.7. Ailerons attachment joints

2.7.1. Aileron attachment on the wing rib No.19

[mm] [mm]
1 2 3 4
1 28.00.3501.015.001/002
2 28.00.3510.003.003/004 7H7 9H8 9,2H8 9,4H8 9,6H8 10.2
3 1-7-D-4-Cd - D = 9u8 D = 9,2u8 D = 9,4u8 D =9,6u8
OST1 11119-73
Repair sleeve
3-8
M28
REPAIR MANUAL
2.7.2. Aileron attachment on the wing rib No. 22

[mm] [mm]
1 2 3 4
1 28.00.3501.015.003/004
2 28.00.3510.003.005/006 7H7 9H8 9,2H8 9,4H8 9,6H8 10.2
3 1-7-5-D-Cd - D = 9u8 D = 9,2u8 D = 9,4u8 D =9,6u8
OST1 11119-73
Repair sleeve

[mm] [mm]
1 2 3 4
1 28.00.3501.015.001/002
2 28.00.3510.003.007/008 7H7 9H8 9,2H8 9,4H8 9,6H8 10.2
3 1-7-D-4-Cd - D = 9u8 D = 9,2u8 D = 9,4u8 D =9,6u8
OST1 11119-73
Repair sleeve
3-9
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3501.030.001/002
2 28.00.3510.005.001/002 10H8 10,2H8 10,42H8 10,6H8 10,8H8 11.0
3 1-8-D-12-1,5Cd D D= D = 10,4u8 D = 10,6u8 D =10,8u8
OST1 11124-73 =10u8 10,2u8
Repair sleeve
2.8. Inner spoiler attachment joints

2.8.1. Spoiler attachment on rib No. 12

[mm] [mm]
1 2 3 4
1 28.00.3765.050.001/002 8H8 8,2H8 8,4H8 8,6H8 8,8H8 4,5
2 28.00.3801.420.001/002
3 1-6-D-3-1,5Cd D=8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D =8,8u8
OST 111124-73
3-10
M28
REPAIR MANUAL
2.8.2. Inner spoiler control attachment, rib No. 14
Detail A
Detail B

[mm] [mm]
1 2 3 4
Detail A
1 28.00.3801.410.001/002 8H8 8,2H8 8,4H8 8,6H8 8,8H8 4,6
2 28.00.5751.110.000
3 1-6-D-4-1,5 D=8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D =8,8u8
OST 111125-73
Detail B
1 28.00.3801.410.001/002 8H8 8,2H8 8,4H8 8,6H8 8,8H8 4,6
2 28.00.3720.220.000
3 1-6-D-4-1,5 D=8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D =8,8u8
OST1 11125-73
3-11
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3765.051.001/002 8H8 8,2H8 8,4H8 8,6H8 8,8H8 4,5
2 28.00.3801.420.001/002
3 1-6-D-3-1,5Cd D=8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D =8,8u8
OST 111124-73
2.8.4. Inner spoiler control attachment joint on the wing

[mm] [mm]
1 2 3 4
1 28.00.2100.002.001/002 9H8 9,2H8 9,4H8 9,6H8 9,8H8 8
2 28.00.5751.120.001/002
3 1-6-D-4-1,5Chem.Pas. D=9u8 D = 9,2u8 D = 9,4u8 D = 9,6u8 D = 9,8u8
OST1 11125-79
3-12
M28
REPAIR MANUAL
2.9. Outer spoiler attachment joints

2.9.1. Outer spoiler control

[mm] [mm]
1 2 3 4
1 28.00.3802.403.000 8H8 8,2H8 8,4H8 8,6H8 8,8H8 5,6
2 28.00.5755.115.000
3 1-6-D-3-1,5Chem.Pas. D =8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D = 8,8u8
OST1 11125-73

[mm] [mm]
1 2 3 4
1 28.00.3802.402.001/002 8H8 8,2H8 8,4H8 8,6H8 8,8H8 5,6
2 28.00.3775.050.001/002
3 1-6-D-3-1,5Chem.Pas. D=8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D = 8,8u8
OST1 11125-73
3-13
M28
REPAIR MANUAL
2.9.3. Spoiler attachment on rib No. 27 and rib No. 28

[mm] [mm]
1 2 3 4
1 28.00.3802.402.001/002 8H8 8,2H8 8,4H8 8,6H8 8,8H8 5,6
2 28.00.3775.051.001/002
3 1-6-D-3-1,5Chem.Pas. D=8u8 D = 8,2u8 D = 8,4u8 D = 8,6u8 D =8,8u8
OST1 11125-73
2.10. Aileron trimmer control joint

[mm] [mm]
1 2 3 4
1 28.00.3727.011.000 7H7 7,2H8 7,4H8 7,6H8 7,8H8 4,0
2 28.00.3525.005.000 7H8 7,2H8 7,4H8 7,6H8 7,8H8 3,1
3 1-5-D-3-1,5Cd D =7u8 D = 7,2u8 D = 7,4u8 D = 7,6u8 D = 7,8u8
OST1 11127-73
4 4-5-D-3-1,5Cd D =7u8 D = 7,2u8 D = 7,4u8 D = 7,6u8 D = 7,8u8
OST1 11127-73
3-14
M28
REPAIR MANUAL
3-15
M28
REPAIR MANUAL
3-16
M28
REPAIR MANUAL
2.14. Slats-to-outboard wing attachment joints

2.14.1. Fitting on the slat, slat rocker, rib No. 11

[mm] [mm]
1 2 3 4
1 28.00.3610.001.001 9H7 11H8 11,2H8 11,4H8 11,6H8 7,2
2 28.00.3601.001.001
3 1-9-D-7,5-Cd - 11u8 11,2u8 11,4u8 11,6u8
OST1 11119-73
Repair sleeve
3-17
M28
REPAIR MANUAL
2.14.2. Bracket on the nose, slat rocker, rib No. 11

[mm] [mm]
1 2 3 4
1 28.00.3610.001.001
2 28.00.3610.038.001/002 9H7 11H8 11,2H8 11,4H8 11,6H8 14,2
3 1-9-D-6,5-Cd - 11u8 11,2u8 11,4u8 11,6u8
OST1 11119-73
Repair sleeve
3-18
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.001.003 9H7 11H8 11,2H8 11,4H8 11,6H8 7,2
2 28.00.3601.001.003
3 1-9-D-7,5-Cd - 11u8 11,2u8 11,4u8 11,6u8
OST1 11119-73
Tulejka remontowa
Repair sleeve
3-19
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.001.003
2 28.00.3610.039.001/002 9H7 11H8 11,2H8 11,4H8 11,6H8 14,2
3 1-9-D-6,5-Cd - 11u8 11,2u8 11,4u8 11,6u8
OST1 11119-73
Repair sleeve
3-20
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.001.001 9H7 11H8 11,2H8 11,4H8 11,6H8 7,2
2 28.00.3601.001.005
3 1-9-D-7,5-Cd - 11u8 11,2u8 11,4u8 11,6u8
OST1 11119-73
Repair sleeve
3-21
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.001.001
2 28.00.3610.039.003/004 9H7 11H8 11,2H8 11,4H8 11,6H8 14,2
3 1-9-D-6,5-Cd - 11u8 11,2u8 11,4u8 11,6u8
OST1 11119-73
Repair sleeve
3-22
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.002.001 7H7 9H8 9,2H8 9,4H8 9,6H8 6,2
2 28.00.3602.001.001
3 1-7-D-5,5-Cd - 9u8 9,2u8 9,4u8 9,6u8
OST1 11119-73
Repair sleeve
3-23
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.002.001
2 28.00.3610.040.001/002 7H7 9H8 9,2H8 9,4H8 9,6H8 10,2
3 1-7-D-5-Cd - 9u8 9,2u8 9,4u8 9,6u8
OST1 11119-73
Repair sleeve
3-24
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.002.003
2 28.00.3610.040.003/004 7H7 9H8 9,2H8 9,4H8 9,6H8 10,2
3 1-7-D-5-Cd - 9u8 9,2u8 9,4u8 9,6u8
OST1.11119-73
Repair sleeve
3-25
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.002.003 7H7 9H8 9,2H8 9,4H8 9,6H8 6,2
2 28.00.3602.001.003
3 1-7-D-5,5-Cd - 9u8 9,2u8 9,4u8 9,6u8
OST1.11119-73
Repair sleeve
3-26
M28
REPAIR MANUAL
2.14.11. Bracket on the slat, slat rocker, rib No. 28

[mm] [mm]
1 2 3 4
1 28.00.3610.002.005
2 28.00.3610.041.001/002 7H7 9H8 9,2H8 9,4H8 9,6H8 10,2
3 1-7-D-5-Cd - 9u8 9,2u8 9,4u8 9,6u8
OST1 11119-73
Repair sleeve
3-27
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3610.002.005 7H7 9H8 9,2H8 9,4H8 9,6H8 6,2
2 28.00.3602.002.005
3 1-7-D-5,5-Cd - 9u8 9,2u8 9,4u8 9,6u8
OST1 11119-73
Repair sleeve
3-28
M28
REPAIR MANUAL
3. EMPENNAGE
1. Tail plane attachment joints on the fuselage

2. Elevators attachment joints
3. Rudders attachment joints
3-29
M28
REPAIR MANUAL
3.1. Tail plane attachment joints on the fuselage
Detail A

[mm] [mm]
1 2 3 4
1 28.00.3100.105.001/002 10H9 10,5H9 11H9 11,5H9 12H9 10
2 28.00.0929.001.000 10H9 10,5H9 11H9 11,5H9 12H9 14
3 3031A-D-40-4 10 10,5 11 11,5 12 Torque for
D=10,5, 11,
11,5 - 1,06 0,1 kGm,
for
D=12 - 1,5 0,1 kGm
Detail B

[mm] [mm]
1 2 3 4
1 28.00.3100.109.001/002 10H9 10,5H9 11H9 11,5H9 12H9 9
2 28.00.0931.001.000 10H9 10,5H9 11H9 11,5H9 12H9 9
3 3031A-D-40-4 10 10,5 11 11,5 12 Torque for D=10,5, 11,
11,5 - 1,06 0,1 kGm,
for
D=12 - 1,5 0,1 kGm
3-30
M28
REPAIR MANUAL
3.2. Elevators attachment joints
Details A1, A2
Effective up to AJE003-01
[mm] [mm]
1 2 3 4
Detail A1, A2
1 28.00.3102.021.000 9H9 9,5H9 10H9 10,5H9 11H9 10
2 28.00.3102.022.000 9H9 9,5H9 10H9 10,5H9 11H9 10
3 28.00.3200.001.000 9H7 9,5H7 10H7 10,5H7 11H7 9
28.14.3000.011.003 9 9,5 10 10,5 11 Torque for thread
Detail A1 8,5 9, 9,5 -
4 1.06 0,1 kGm,
For
28.14.3000.011.004 9 9,5 10 10,5 11 10 - 1,5 0,1 kGm
Detail A2
Effective from AJE003-02

[mm] [mm]
1 2 3 4
Detail A1, A2
1 28.00.3102.021.000 8H9 8,5H9 9H9 9,5H9 10H9 10
2 28.00.3102.022.000 8H9 8,5H9 9H9 9,5H9 10H9 10
3 28.00.3200.001.000 8H7 8,5H7 9H7 9,5H7 10H7 9
2-D-58-Cd-OST1.31125 8 8,5 9 9,5 10 Torque for thread
Detail A1 8,5 9, 9,5 -
1.06 0,1 kGm,
4 For
2-D-56-Cd-OST1.31125 8 8,5 9 9,5 10 10 - 1,5 0,1 kGm
Detail A2
3-31
M28
REPAIR MANUAL
Detail B

[mm] [mm]
1 2 3 4
1 28.00.3200.001.000 22N7 4,5 Carry out repair
by bearings
replacement
4 3036Ju1 ETU 100/5
2 28.00.3201.003.000 8H7 8,2H7 8,4H7 8,6H7 8,8H7 7 Put on repair
/u8 /u8 /u8 /u8 /u8 sleeves
5 4-6-D-5-1kd
OST1 11124-73
6 6X30-2-ZN-77/L-1111-06
Detail C

[mm] [mm]
1 2 3 4
1 28.00.3203.010.000 50h6 Carry out repair
by bearings
replacement
2 28.00.3202.031.000 65M7 6
3 OU-900810 Ju or
900810 Ju U ETU100/5
3-32
M28
REPAIR MANUAL
Detail D
[mm] [mm]
1 2 3 4
1 28.00.3203.031.000 7H9 7,5H9 8H9 8,5H9 9H9 7
9H9 9,5H9 10H9 10,5H9 11H9 10
2 28.00.3102.020.000 7H9 7,5H9 8H9 8,5H9 9H9 11 Torque for thread
9H9 9,5H9 10H9 10,5H9 11H9 10 diametr 6,5, 7, 7,5
-0,475 0,05 kGm,
for 8, 8,5, 9, 9,5-
1,06 0,1 kGm
for 10 - 1,5 0,1
kGm
3 28.14.3000.011.001 9 9,5 10 10,5 11
4 28.14.3000.012.001 7 7,5 8 8,5 9

[mm] [mm]
1 2 3 4
1 28.00.3203.031.000 6H9 6,5H9 7H9 7,5H9 8H9 7
8H9 8,5H9 9H9 9,5H9 10H9 10
2 28.00.3102.020.000 6H9 6,5H9 7H9 7,5H9 8H9 11 Torque for thread
8H9 8,5H9 9H9 9,5H9 10H9 10 diametr 6,5, 7, 7,5
-0,475 0,05 kGm,
for 8, 8,5, 9, 9,5-
1,06 0,1 kGm
for
10 - 1,5 0,1 kGm
3 2-D-64-Cd-OST1.31125 8 8,5 9 9,5 10
4 2-D-62-Cd-OST1.31125 6 6,5 7 7,5 8
3-33
M28
REPAIR MANUAL
3.3. Rudders attachment joints Details A1, A2
[mm] [mm]
1 2 3 4
Detail A1, A2
1 28.00.3402.030.000 9H9 9,5H9 10H9 10,5H9 11H9 10
2 28.00.3402.040.000 9H9 9,5H9 10H9 10,5H9 11H9 10
3 28.00.3300.130.000 9H7 9,5H7 10H7 10,5H7 11H7 10
28.14.3000.011.003 9 9,5 10 10,5 11 Torque for thread
Detail A1 8,5 9, 9,5 -
1.06 0,1 kGm,
4 for
28.14.3000.011.004 9 9,5 10 10,5 11 10 - 1,5 0,1 kGm
Detail A2

[mm] [mm]
1 2 3 4
Detail A1, A2
1 28.00.3402.030.000 8H9 8,5H9 9H9 9,5H9 10H9 10
2 28.00.3402.040.000 8H9 8,5H9 9H9 9,5H9 10H9 10
3 28.00.3300.130.000 8H7 8,5H7 9H7 9,5H7 10H7 10
2-D-58-Cd-OST1.31125 8 8,5 9 9,5 10 Torque for thread
Detail A1 8,5 9, 9,5 -
1.06 0,1 kGm,
4 for
2-D-56-Cd-OST1.31125 8 8,5 9 9,5 10 10 - 1,5 0,1 kGm
Detail A2
3-34
M28
REPAIR MANUAL
Detail B

[mm] [mm]
1 2 3 4
1 28.00.3300.130.000 22N7 5,5 Carry out repair
n by bearings
replacement
4 3036Ju1 ETU 100/5
5 1-6-D-7-1Chem.pas.
OST1 11125-73
3 28.00.3301.020.000 8H7 8,2H7 8,4H7 8,5H7 8,8H7 11
/u8 /u8 /u8 /u8 /u8
6 6X38-2-ZN-77/L-1111-06
Detail C
[mm] [mm]
1 2 3 4
1 28.00.3300.140.000 7H9 7,5H9 8H9 8,5H9 9H9 11
9H9 9,5H9 10H9 10,5H9 11H9
2 28.00.3402.020.000 7H9 7,5H9 8H9 8,5H9 9H9 10 For thread
9H9 9,5H9 10H9 10,5H9 11H9 diameter 6,5, 7, 7,5
-0,475 0,05 kGm,
for 8, 8,5, 9, 9,5 -
1,06 0,1 kGm,
for 10 - 1,5 0,1
kGm
3 28.14.3000.012.002 7 7,5 8 8.5 9
4 28.14.3000.011.002 9 9,5 10 10.5 11
3-35
M28
REPAIR MANUAL

[mm] [mm]
1 2 3 4
1 28.00.3300.140.000 6H9 6,5H9 7H9 7,5H9 8H9 11
8H9 8,5H9 9H9 9,5H9 10H9
2 28.00.3402.020.000 6H9 6,5H9 7H9 7,5H9 8H9 10 For thread
8H9 8,5H9 9H9 9,5H9 10H9 diameter 6,5, 7, 7,5
-0,475 0,05 kGm,
for 8, 8,5, 9, 9,5 -
1,06 0,1 kGm,
for 10 - 1,5 0,1
kGm
3 2-D-60-Cd-OST1.31125 6 6,5 7 7.5 8
4 2-D-60-Cd-OST1.31125 8 8,5 9 9.5 10
Detail D

[mm] [mm]
1 2 3 4
1 28.00.3301.030.000 10H8 10,2H8 10,4H8 10,6H8 10,8H8 6 i 14 Put on repair
4 1-8-D-8-1,5 Chem.pas.
OST1 11125-73
2 28.00.3300.140.000 28N7n 7,5 Carry out repair
by bearings
replacement
3 83078 Ju 2S2
5 8X38-2-
ZN-77/L-1111-06
3-36
M28
REPAIR MANUAL
4. MAIN LANDING GEAR
1. Connecting rod-to-main landing gear assy attachment bottom point

2. Main landing gear connecting rod-to bracket of the landing gear attachment
in the fuselage upper joint.
3. Main landing gear assy-to bracket of the landing gear attachment
in the fuselage front joint
3-37
M28
REPAIR MANUAL
4.1. Connecting rod-to-main landing gear assy attachment bottom joint

[mm] [mm]
1 2 3 4
1 28.00.4110.100.000 30H7 - - - -
2 28.00.4100.101.003 30h8 - - - -
3 28.00.4100.114.000 30H9
40f7 40,1f7 40,2f7 40,3f7 40,4f7
4 28.00.4100.113.000 40H7 40,1H7 40,2H7 40,3H7 40,4H7
5 28.00.4100.102.003 30H9
40H11 40,1H11 40,2H11 40,3H11 40,4H11
3-38
M28
REPAIR MANUAL
4.2. Main landing gear connecting rod-to bracket of the landing gear attachment in the
fuselage upper joint

[mm] [mm]
1 2 3 4
1 28.00.0230.090.001/00 34H7 34,2H7 34,4H7 - -
2
2 28.00.0230.075.000 34u8 34,2u8 34,4u8 - -
3 28.00.4100.101.005 30h8
4 28.00.4100.114.000 30H9
40f7 40,1f7 40,2f7 40,3f7 40,4f7
5 28.00.4100.113.000 40H7 40,1H7 40,2H7 40,3H7 40,4H7
6 28.00.4100.102.005 30H9
40H11 40,1H11 40,2fH11 40,3H11 40,4H11
3-39
M28
REPAIR MANUAL
4.3. Main landing gear assy-to bracket of the landing gear attachment in the fuselage
front joint

[mm] [mm]
1 2 3 4
1 28.00.4110.008.000 60g7 - - - -
2 28.00.4112.000.000 60H7 - - - -
3 28.00.0230.074.000 60H7 - - - - Put on sleeve on
65u8 65,2u8 65,4u8 65,6u8 WK-9 adhesive
4 28.00.0230.090.001/002 65H8 - 65,2H8 65,4H8 65,6H8
3-40
M28
REPAIR MANUAL
5. FIT INTERCHANGERS
Diameter Shaft or hole Tolerance Dimension

mm in
ø6 H9 +0.036
0
6.03600
6.00000
0.2376378
0.2362204
ø6.5 H9 +0.036
0
6.53600
6.50000
0.2573228
0.2559055
ø7 H7 +0.015
0
7.01500
7.00000
0.2761811
0.2755905
ø7 H8 +0.022
0
7.02200
7.00000
0.2764566
0.2755905
ø7.2 H8 +0.022
0
7.22200
7.20000
0.2843307
0.2834645
ø7.4 H8 +0.022
0
7.42200
7.40000
0.2922047
0.2913385
ø7.6 H8 +0.022
0
7.62200
7.60000
0.3000787
0.2992126
ø7.8 H8 +0.022
0
7.82200
7.80000
0.3079527
0.3070866
ø7 H9 +0.036
0
7.03600
7.00000
0.2770078
0.2755905
ø7.5 H9 +0.036
0
7.53600
7.50000
0.2966929
0.2952755
ø7 u8 +0.050
+0.028
7.05000
7.02800
0.2775590
0.2766929
ø7.2 u8 +0.050
+0.028
7.25000
7.22800
0.2854330
0.2845669
ø7.4 u8 +0.050
+0.028
7.45000
7.42800
0.2933070
0.2924409
ø7.6 u8 +0.050
+0.028
7.65000
7.62800
0.3011811
0.3003149
ø7.8 u8 +0.050
+0.028
7.85000
7.82800
0.3090551
0.3081889
ø8.2 f9 -0.013
-0.049
8.18700
8.15100
0.3223228
0.3209055
ø8.5 f9 -0.013
-0.049
8.48700
8.45100
0.3341338
0.3327165
ø8 H8 +0.022
0
8.02200
8.00000
0.3158267
0.3149606
ø8.2 H8 +0.022
0
8.22200
8.20000
0.3237007
0.3228346
ø8.4 H8 +0.022
0
8.42200
8.40000
0.3315748
0.3307086
ø8.5 H8 +0.022
0
8.52200
8.50000
0.3355118
0.3346456
ø8.6 H8 +0.022
0
8.62200
8.60000
0.3394488
0.3385826
ø8.8 H8 +0.022
0
8.82200
8.80000
0.3473228
0.3464566
Revision 2 3-41
M28
REPAIR MANUAL

mm in
ø8 H7 +0.015
0
8.01500
8.00000
0.3155511
0.3149606
ø8.2 H7 +0.015
0
8.21500
8.20000
0.3234252
0.3228346
ø8.4 H7 +0.015
0
8.41500
8.40000
0.3312992
0.3307086
ø8.6 H7 +0.015
0
8.61500
8.60000
0.3391732
0.3385826
ø8.8 H7 +0.015
0
8.81500
8.80000
0.3470472
0.3464566
ø8 u8 +0.050
+0.028
8.05000
8.02800
0.3169291
0.3160629
ø8.2 u8 +0.050
+0.028
8.25000
8.22800
0.3248031
0.3239370
ø8.4 u8 +0.050
+0.028
8.45000
8.42800
0.3326771
0.3318110
ø8.6 u8 +0.050
+0.028
8.65000
8.62800
0.3405511
0.3396850
ø8.8 u8 +0.050
+0.028
8.85000
8.82800
0.3484252
0.3475590
ø8 H9 +0.036
0
8.85000
8.82800
0.3484252
0.3475590
ø8.5 H9 +0.036
0
8.03600
8.00000
0.3163779
0.3149606
ø9 H7 +0.015
0
9.01500
9.00000
0.3549212
0.3543307
ø9.5 H7 +0.015
0
9.51500
9.50000
0.3746063
0.3740157
ø9 H8 +0.022
0
9.02200
9.00000
0.3551968
0.3543307
ø9.2 H8 +0.022
0
9.22200
9.20000
0.3630708
0.3622047
ø9.4 H8 +0.022
0
9.42200
9.40000
0.3709448
0.3700787
ø9.6 H8 +0.022
0
9.62200
9.60000
0.3788189
0.3779527
ø9.8 H8 +0.022
0
9.82200
9.80000
0.3866929
0.3858267
ø9 H9 +0.036
0
9.03600
9.00000
0.3557480
0.3543307
ø9.5 H9 +0.036
0
9.53600
9.50000
0.3754330
0.3740157
ø9 u8 +0.050
+0.028
9.05000
9.02800
0.3563992
0.3554330
ø9.2 u8 +0.050
+0.028
9.25000
9.22800
0.3641732
0.3533070
ø9.4 u8 +0.050
+0.028
9.45000
9.42800
0.3720472
0.3711811
3-42 Revision 2
M28
REPAIR MANUAL

mm in
ø9.6 u8 +0.050
+0.028
9.65000
9.62800
0.3799212
0.3790551
ø9.8 u8 +0.050
+0.028
9.85000
9.82800
0.3877952
0.3869291
ø10 H7 +0.018
0
10.01800
10.00000
0.3944094
0.3937007
ø10.5 H7 +0.018
0
10.51800
10.50000
0.4140944
0.4133858
ø10 H8 +0.027
0
10.02700
10.00000
0.3947637
0.3937007
ø10.2 H8 +0.027
0
10.22700
10.20000
0.4026378
0.4015748
ø10.4 H8 +0.027
0
10.42700
10.40000
0.4105118
0.4094488
ø10.6 H8 +0.027
0
10.62700
10.60000
0.4183858
0.4173228
ø10.8 H8 +0.027
0
10.82700
10.80000
0.4262598
0.4251968
ø10 u8 +0.060
+0.033
10.06000
10.03300
0.3960629
0.3950000
ø10.2 u8 +0.060
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10.26000
10.23300
0.4039370
0.4028740
ø10.4 u8 +0.060
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10.46000
10.43300
0.4118110
0.4107480
ø10.6 u8 +0.060
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10.66000
10.63300
0.4196685
0.4186220
ø10.8 u8 +0.060
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10.86000
10.83300
0.4275590
0.4264960
ø10 H9 +0.043
0
10.04300
10.00000
0.3953937
0.3937007
ø10.5 H9 +0.043
0
10.54300
10.00000
0.4150787
0.3937007
ø11 H7 +0.018
0
11.01800
11.00000
0.4337795
0.4330708
ø11 H8 +0.027
0
11.02700
11.00000
0.4341338
0.4330708
ø11.2 H8 +0.027
0
11.22700
11.20000
0.4420078
0.4409448
ø11.4 H8 +0.027
0
11.42700
11.40000
0.4498818
0.4488189
ø11.6 H8 +0.027
0
11.62700
11.60000
0.4577559
0.4566929
ø11 u8 +0.060
+0.033
11.06000
11.03300
0.4354330
0.4343700
ø11.2 u8 +0.060
+0.033
11.26000
11.23300
0.4433070
0.4422440
ø11.4 u8 +0.060
+0.033
11.46000
11.43300
0.4511811
0.4501181
ø11.6 u8 +0.060
+0.033
11.66000
11.63300
0.4590551
0.4579921
Revision 2 3-43
M28
REPAIR MANUAL

mm in
ø11 H9 +0.043
0
11.04300
11.00000
0.4347637
0.4330708
ø11.5 H9 +0.043
0
11.54300
11.50000
0.4544488
0.4527559
ø12 H7 +0.018
0
12.01800
12.00000
0.4731496
0.4724409
ø12.2 H7 +0.018
0
12.21800
12.20000
0.4810236
0.4803149
ø12.4 H7 +0.018
0
12.41800
12.40000
0.4888976
0.4881889
ø12.5 H7 +0.018
0
12.51800
12.50000
0.4928346
0.4921259
ø12.6 H7 +0.018
0
12.61800
12.60000
0.4967716
0.4960629
ø12.8 H7 +0.018
0
12.81800
12.80000
0.5046456
0.5039370
ø12 f7 -0.016
-0.034
11.98400
11.96600
0.4718110
0.4711023
ø12.2 f7 -0.016
-0.034
12.18400
12.16600
0.4796850
0.4789763
ø12.4 f7 -0.016
-0.034
12.38400
12.36600
0.4875590
0.4868503
ø12.5 f7 -0.016
-0.034
12.48400
12.46600
0.4914960
0.4907870
ø12.6 f7 -0.016
-0.034
12.58400
12.56600
0.4954330
0.4947244
ø12.8 f7 -0.016
-0.034
12.78400
12.76600
0.5033070
0.5025984
ø12 H9 +0.043
0
12.04300
12.00000
0.4741338
0.4724409
ø13 H7 +0.018
0
13.01800
13.00000
0.5125196
0.5118110
ø13.5 H7 +0.018
0
13.51800
13.50000
0.5322047
0.5314960
ø13 f7 -0.016
-0.034
12.98400
12.96600
0.5111811
0.5104724
ø13.5 f7 -0.016
-0.034
13.48400
13.46600
0.5308661
0.5301574
ø14 H7 +0.018
0
14.01800
14.00000
0.5518897
0.5511811
ø14 f7 -0.016
-0.034
13.98400
13.96600
0.5505511
0.5498425
ø15 H7 +0.018
0
15.01800
15.00000
0.5912598
0.5905511
ø15.2 H7 +0.018
0
15.21800
15.20000
0.5991338
0.5984252
ø15.4 H7 +0.018
0
15.41800
15.40000
0.6070078
0.6062992
3-44 Revision 2
M28
REPAIR MANUAL

mm in
ø15.6 H7 +0.018
0
15.61800
15.60000
0.6148818
0.6141732
ø15.8 H7 +0.018
0
15.818.00
15.80000
0.6227559
0.6220472
ø15 u8 +0.060
+0.033
15.06000
15.03300
0.5929133
0.5918503
ø15.2 u8 +0.060
+0.033
15.26000
15.23300
0.6007874
0.5997744
ø15.4 u8 +0.060
+0.033
15.46000
15.43300
0.6086614
0.6075984
ø15.6 u8 +0.060
+0.033
15.66000
15.63300
0.6165354
0.6154724
ø15.8 u8 +0.060
+0.033
15.86000
15.83300
0.6244094
0.6233464
ø16 H7 +0.018
0
16.01800
16.00000
0.6306299
0.6299212
ø16.5 H7 +0.018
0
16.51800
16.50000
0.6503149
0.6496063
ø16 f7 -0.016
-0.034
15.98400
15.96600
0.6292913
0.6285826
ø16.5 f7 -0.016
-0.034
16.48400
16.46600
0.6489763
0.6482677
ø17 H7 +0.018
0
17.01800
17.00000
0.6700000
0.6692913
ø17.5 H7 +0.018
0
17.51800
17.50000
0.6896850
0.6889763
ø17 f7 -0.016
-0.034
16.98400
16.96600
0.6686614
0.6679527
ø17.5 f7 -0.016
-0.034
17.48400
17.46600
0.6883464
0.6876378
ø18 H7 +0.018
0
18.01800
18.00000
0.7093700
0.7086614
ø18 f7 -0.016
-0.034
17.98400
17.96600
0.7080315
0.7073228
ø20 H9 +0.052
0
20.05200
20.00000
0.7894488
0.7874015
ø20.2 H9 +0.052
0
20.25200
20.20000
0.7973228
0.7952755
ø20.4 H9 +0.052
0
20.45200
20.40000
0.8051968
0.8031496
ø20.8 H9 +0.052
0
20.85200
20.80000
0.8209448
0.8188976
ø20 h6 0
-0.013
20.00000
19.98700
0.7874015
0.7868897
ø20.2 h6 0
-0.013
20.20000
20.18700
0.7952755
0.7947637
ø20.4 h6 0
-0.013
20.40000
20.38700
0.8031496
0.8026378
Revision 2 3-45
M28
REPAIR MANUAL

mm in
ø20.6 h6 0
-0.013
20.60000
20.58700
0.8110236
0.8105118
ø20.8 h6 0
-0.013
20.80000
20.78700
0.8188976
0.8183858
ø22 H8 +0.033
0
22.03300
22.00000
0.8674409
0.8661417
ø22.2 H8 +0.033
0
22.23300
22.20000
0.8753149
0.8740157
ø22.4 H8 +0.033
0
22.43300
22.40000
0.8831889
0.8818897
ø22.6 H8 +0.033
0
22.63300
22.60000
0.8910629
0.8897637
ø22 u8 +0.074
+0.041
22.07400
22.04100
0.8690551
0.8677559
ø22.2 u8 +0.074
+0.041
22.27400
22.24100
0.8769291
0.8756299
ø22.4 u8 +0.074
+0.041
22.47400
22.44100
0.8848031
0.8835039
ø22.6 u8 +0.074
+0.041
22.67400
22.64100
0.8926771
0.8913779
ø22 N7 -0.007
-0.028
21.99300
21.97200
0.8658661
0.8650393
ø24 H8 +0.033
0
24.03300
24.00000
0.9461811
0.9448818
ø24.2 H8 +0.033
0
24.23300
24.20000
0.9540551
0.9527559
ø24.4 H8 +0.033
0
24.43300
24.40000
0.9619291
0.9606299
ø24.6 H8 +0.033
0
24.63300
24.60000
0.9698031
0.9685039
ø24.8 H8 +0.033
0
24.83300
24.80000
0.9776771
0.9763779
ø24 u8 +0.081
+0.048
24.08100
24.04800
0.9698031
0.9685039
ø24.2 u8 +0.081
+0.048
24.28100
24.24800
0.9559448
0.9546456
ø24.6 u8 +0.081
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24.68100
24.64800
0.9716929
0.9703937
ø24.8 u8 +0.081
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24.88100
24.84800
0.9795669
0.9782677
ø28 N7 -0.007
-0.028
27.99300
27.97200
1.1020866
1.1012598
ø30 H7 +0.021
0
30.02100
30.00000
1.1819291
1.1811024
ø30 h8 0
-0.033
30.00000
29.96700
1.1811024
1.1798031
ø30 H9 +0.052
0
30.05200
30.00000
1.1831496
1.1811024
3-46 Revision 2
M28
REPAIR MANUAL

mm in
ø34 H7 +0.025
0
34.02500
34.00000
1.3395669
1.3385827
ø34.2 H7 +0.025
0
34.22500
34.20000
1.3474409
1.3464567
ø34.4 H7 +0.025
0
34.42500
34.40000
1.3553150
1.3543307
ø34 u8 +0.099
+0.060
34.09900
34.06000
1.3424803
1.3409449
ø34.2 u8 +0.099
+0.060
34.29900
34.26000
1.3503543
1.3488189
ø34.4 u8 +0.099
+0.060
34.49900
34.46000
1.3582283
1.3566929
ø35 H7 +0.025
0
35.02500
35.00000
1.3789370
1.3779528
ø35.1 H7 +0.025
0
35.12500
35.10000
1.3828740
1.3818898
ø35.2 H7 +0.025
0
35.22500
35.20000
1.3868110
1.3858268
ø40 H7 +0.025
0
40.02500
40.00000
1.5757874
1.5748031
ø40.1 H7 +0.025
0
40.12500
40.10000
1.5797244
1.5787402
ø40.2 H7 +0.025
0
40.22500
40.20000
1.5836614
1.5826772
ø40.3 H7 +0.025
0
40.32500
40.30000
1.5879840
1.5866142
ø40.4 H7 +0.025
0
40.42500
40.40000
1.5915354
1.5905512
ø40 H11 +0.160
0
40.16000
40.00000
1.5811024
1.5748031
ø40.1 H11 +0.160
0
40.26000
40.10000
1.5850340
1.5787402
ø40.2 H11 +0.160
0
40.36000
40.20000
1.5889764
1.5826772
ø40.3 H11 +0.160
0
40.46000
40.30000
1.5929134
1.5866142
ø40 f7 -0.025
-0.050
39.97500
39.95000
1.5738189
1.5728346
ø40.1 f7 -0.025
-0.050
40.07500
40.05000
1.5777590
1.5767717
ø40.2 f7 -0.025
-0.050
40.17500
40.15000
1.5816929
1.5807087
ø40.3 f7 -0.025
-0.050
40.27500
40.25000
1.5856299
1.5846457
ø40.4 f7 -0.025
-0.050
40.37500
40.35000
1.5895669
1.5885827
ø41 H8 +0.039
0
41.03900
41.00000
1.6157087
1.6141732
ø41.2 H8 +0.039
0
41.23900
41.20000
1.6235827
1.6220472
Revision 2 3-47
M28
REPAIR MANUAL

mm in
ø41.4 H8 +0.039
0
41.43900
41.40000
1.6314567
1.6299213
ø41.6 H8 +0.039
0
41.63900
41.60000
1.6393307
1.6377953
ø41.8 H8 +0.039
0
41.83900
41.80000
1.6472047
1.6456693
ø41 u8 +0.109
+0.070
41.10900
41.07000
1.6184646
1.6169291
ø41.2 u8 +0.109
+0.070
41.30900
41.27000
1.6177165
1.6248031
ø41.4 u8 +0.109
+0.070
41.50900
41.47000
1.6342126
1.6367720
ø41.6 u8 +0.109
+0.070
41.70900
41.67000
1.6420866
1.6405512
ø41.8 u8 +0.109
+0.070
41.90900
41.87000
1.6499606
1.6484252
ø50 h6 0
-0.019
50.00000
49.98100
1.9685039
1.9677559
ø60 g7 -0.010
-0.040
59.99000
59.96000
2.3618110
2.3606299
ø60 H7 +0.030
0
60.03000
60.00000
2.3633858
2.3622047
ø65 u8 +0.148
+0.102
65.14800
65.10200
2.5648819
2.5630709
ø65.2 u8 +0.148
+0.102
65.34800
65.30200
2.5727559
2.5709449
ø65.4 u8 +0.148
+0.102
65.54800
65.50200
2.5727559
2.5788189
ø65.6 u8 +0.148
+0.102
65.74800
65.70200
2.5885039
2.5866929
ø65 H8 +0.046
0
65.04600
65.00000
2.5608661
2.5590551
ø65.2 H8 +0.046
0
65.24600
65.20000
2.5687402
2.5669291
ø65.4 H8 +0.046
0
65.44600
65.40000
2.5766142
2.5748031
ø65.6 H8 +0.046
0
65.64600
65.60000
2.5844882
2.5826772
ø65 M7 0
-0.030
65.00000
64.97000
2.5590551
2.5578740
3-48 Revision 2
M28
REPAIR MANUAL
Page
1. SERVICE LIFE OF AIRFRAME, LANDING GEAR, ENGINE,

PROPELLER AND AIRFRAME UNITS................................................................................... 4-1
2. SERVICE LIFE OF RUBBER HOSES ..................................................................................... 4-2
3. SUBSTITUTES OF THE RUBBER HOSES ............................................................................ 4-3
Revision 3 Contents
M28
REPAIR MANUAL
1. SERVICE LIFE OF AIRFRAME, LANDING GEAR, ENGINE, PROPELLER AND AIRFRAME

UNITS
Service life of airframe, landing gear, engine, propeller and limited service life of accessories
are specified in the LIST OF MAIN ACCESSORIES AND ASSEMBLIES INSTALLED ON THE
M28 AIRPLANE.
4-1
M28
REPAIR MANUAL
2. SERVICE LIFE OF RUBBER HOSES
Service life (counted since the date of hose manufacture

i.e. the earlier date specified on hose tag). 10 years of operation
Service life (counted since the date of marking hose

connections, i.e. the latest date specified on hose tag). 7 years of operation )*
List of rubber conduits installed on the airplane
Hose No. Location Q-ty Inner dia. Working pressure

2
per A/C in mm psi kG/cm
Fuel system
28.14.6101.341.000 Fuel system 2 0.16 4 213.3 15
28.14.6101.360.000 Fuel system 2 0.55 14 213.3 15
Oil system
28.14.6202.030.000 Oil system 2 0.63 16 213.3 15
28.14.6202.040.000 Oil system 2 0.63 16 213.3 15
28.14.6202.050.000 Oil system 2 0.98 25 213.3 15
28.14.6202.720.000 Oil system 2 0.16 4 213.3 15
Hydraulic system
28.14.5602.181.001 To hydraulic pump 2 0.47 12 71.1 5
28.14.5602.181.002 To hydraulic pump 2 0.31 8 2133 150
28.14.5602.181.003 To hydraulic pump 2 0.24 6 2133 150
28.00.5603.810.001 To flap cylinder in centerwing 1 0.16 4 2133 150
28.00.5603.810.002 To flap cylinder in centerwing 1 0.16 4 2133 150
1-4-2-340 To inner/outer spoilers 4 0.16 4 2133 150
OST110853
28.14.5602.075.001 To door cylinder 2 0.16 4 2133 150
28.14.5602.075.002 To door cylinder 2 0.16 4 2133 150
28.14.5602.075.003 To door blockade 2 0.16 4 2133 150
________________________________
*) After expiring the 7 years of operation, conduits should by annually inspected prior to
admission for further operation. (Max. extension - 10 years of operation), after meeting the
following requirements:
a) Perform the visual inspection of rubber hoses and connecting ends. It is not allowed to
have any mechanical damages (kink cracks).
b) Check the conduits for tightness applying pressure higher by 20% than the working
pressure (see the table given below) for 1 minute. Leakage is not allowed.
c) Check the conduits for clear passage by inserting the balls of the following diameters into
them:
- for hoses from dia. 0.16 in to 0.24 in (4 to 6 mm) - ball dia. should be lower by 0.012 in
(0.3 mm) compared to hose end diameter;
- for hoses of dia. 0.31 in (8 mm) and above - ball dia. should be lower by 0.024 in (0.6
mm) compared to hose end diameter
Ventilation and heating installation rubber connectors are not subject to test procedure
according para "b" and "c".
4-2 Revision 3
M28
REPAIR MANUAL
3. SUBSTITUTES OF THE RUBBER HOSES.
On the aircraft can be used a teflon hoses in the place of the rubber hoses
according to the rubber hoses substitution list which is provided to facilitate the
identification of that hoses.
Service life of the teflon hoses is not limited.
These teflon hoses are operated on technical condition.
Rubber hoses substitutes List
Rubber hose Teflon hose

Fuel system
28.14.6101.341.000 AE718192-1
28.14.6101.360.000 AE718191-1
Oil system
28.14.6202.030.000 AE3663803KO346
28.14.6202.040.000 AE718193-1
28.14.6202.050.000 -------
28.14.6202.720.000 AE3663803E0153
Hydraulic system
28.14.5602.181.001 AE718193-2
28.14.5602.181.002 AE2464093G0143
28.14.5602.181.003 AE2464093G0122
28.00.5603.810.001 AE718194-1
28.00.5603.810.002 AE718194-2
1-4-2-340 OST1.10853 AE264092E0133
28.14.5602.075.001 AE718195-1
28.14.5602.075.002 AE718194-3
28.14.5602.075.003 AE718196-1
Revision 5 4-3

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POLSKIE ZAKŁADY LOTNICZE

Spółka z ograniczoną odpowiedzialnością w Mielcu

Sign. No. M28/1/2001

This Document contains technical data subject to:

Polskie Zakłady Lotnicze sp. z o.o.

EXPORT CONTROL CLASSIFICATION

1. U.S.: ECCN (EAR) 9E991

SECTION I. TYPICAL REPAIRS

SECTION II. MATERIALS USED FOR REPAIR

SECTION III. REPAIR CONNECTIONS

SECTION IV. SERVICE LIFE

Revision 9 Contents 1/1

LOG OF REVISIONS – 2/2 Revision 15

LIST OF VALID PAGES

Revision 15 List of Valid Pages 1/3

LIST OF VALID PAGES

List of Valid Pages 2/3 Revision 10

LIST OF VALID PAGES

Revision 10 List of Valid Pages 3/3

2. LANDING GEAR REPAIR ........................................................................................... 1-51

3. CONTROL SURFACES BALANCE ................................................................................. 1-63

4. CORROSION REMOVAL AND PREVENTION................................................................ 1-69

Revision 10 Contents 1/2

6. REPLACEMENT OF SEALS ....................................................................................... 1-81

7. REPAIR OF ELECTRICAL SYSTEM. GENERAL INFORMATION ........................... 1-87

Contents 2/2 Revision 10

SECTION I. TYPICAL REPAIRS

1. AIRFRAME STRUCTURE REPAIR

Spraying primer or standing primed surfaces may result in release of hexavalent

1.2. CLASSIFICATION OF DAMAGE

- Damage in the region of the integral fuel tanks.

- Cracks at the control surface attachment fittings or the supporting structure.

- Damage to structural parts of the landing gear bracket (console). These

3. Damage requiring replacement is damage that may have an effect on airworthiness

Damage to a removed structural component should be evaluated for possible repair at a

It is import when evaluating and classifying damage, to determine if the damage is to

In cases of uncertainty as to the classification of damage, the aircraft manufacturer

1.2.1. DAMAGE LIMITATIONS

1.2.1.1. Airplane structure

A. Negligible damage limitations

1. Skin scores, and scratches not over deep:

Wing strut: the same as for fuselage;

3. Skin corrosion up to 0,1 mm (0.004 in) deep;

B. Repairable damage limitations:

1. Skin scores, dents and scratches not over deep:

Wing strut: the same as for fuselage.

2. Cracks and punctures of skin:

Fuselage: Cracks and punctures of skin, up to 80 mm in length. Cracks not to

Wing strut: the same as for fuselage

4. Skin corrosion above 0,1 mm (0.004 in) deep;

5. Weakened rivets - max. 10 % in riveted join.

1.2.1.2 Damage limitations for trim tab:

A. Acceptable damage (not resulting in the operation hold up) (Negligible

• Local dent of a up to 1 mm deep;

B. Damage qualifying the trim tab for replacement:

• Skin crack exceeding 25 mm;

A. Acceptable damage (Negligible damage).

2. Exhaust pipes - see paragraph 1.6.

1.3. PREPARATION FOR REPAIR

A. PREPARATION FOR ALUMINUM ALLOY STRUCTURE RIVET REPAIR

4. Round out holes in flat or contoured sheets to form a smooth outline.

B. PREPARATION FOR WING REPAIR IN INTEGRAL FUEL TANK AREA

b) outer wing tanks:

- open three 1 seq. fire valve;